PACKAGED ROOFTOP - WaterFurnace · Water Piping All piping access is within the curb in the compressor section. Piping is usually designed as ‘reverse return’ to equalize flow

IM1250AU 11/17

Installation Information

Water Piping Connections

Electrical

Startup Procedures

Troubleshooting

Preventive Maintenance

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Commercial 3 to 30 TonSingle & Dual Stage Water Source/Geothermal Heat Pump

PACKAGED ROOFTOP

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VERSATEC PACKAGED ROOFTOP INSTALLATION MANUAL

Table of Contents

Model Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Voltage Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Curb Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Center of Gravity and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

System Cleaning and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Freeze Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Compressor Crankcase Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Wiring Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Economizer Enthalpy Operation with Aurora Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Unit Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Damper Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Reference Calculations and Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Compressor and Thermistor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Preventive Maintenance and Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Revision Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

4


Model Nomenclature

VintageA – Factory Use Only

Non-Standard OptionsSS – Standard

FutureN – None

Drain Pan Option2 – Stainless Steel, (Front Draining)4 – Stainless Steel, (Back Draining)

Air Coil Option 3 – All-Aluminum, Uncoated 4 – All-Aluminum, AlumiSealTM

Filter Option A – 1" Throwaway B – 2" MERV 13 C – 2" MERV 8 D – 4" MERV 13

Electrical OptionN – Standard, NoneS – Standard w/IntelliStart® 7

C – Non-Fused DisconnectD – Non-Fused Disconnect w/IntelliStart® 7

E – Non-Fused Disconnect w/GFI Outlet 6

F – Non-Fused Disconnect w/IntelliStart®

& GFI Outlet 6,7

G – Circuit BreakerH – Circuit Breaker w/IntelliStart® 7

J – Circuit Breaker w/GFI Outlet6

K – Circuit Breaker w/IntelliStart®

& GFI Outlet 6,7

Control OptionA – AuoraTM Base ControlB – Aurora Advanced ControlE – Aurora w/UPC DDC ControlF – Aurora w/UPC DDC Control w/LONG – Aurora Advanced w/UPC DDC ControlH – Aurora Advanced w/UPC DDC w/LON

Cabinet OptionS – Standard, No Outdoor AirA – Motorized Outdoor Air Damper B – Dry Bulb Economizer 2,3,5

C – Dry Bulb Economizer w/Barometric Relief 2,3,5

E – Network Controlled Economizer 2,3,4,5

F – Network Controlled Economizer w/Barometric Relief 2,3,4,5

G – Differential Enthalpy Economizer 2,3,5

H – Differential Enthalpy w/Barometric Relief 2,3,5

Future Option000 – None

1-2 3 4-6 7 8 9

Model TypeUR – Versatec Packaged

Rooftop

Compressor ConfigurationS – Single Speed ScrollD – Dual Capacity ScrollT – Two Scroll, Independent Circuit

Unit Capacity (MBTUH)036, 048, 060, 070(Single Speed)038, 049, 064, 072(Dual Capacity)096, 120, 144(Two Compressor)8

180, 181, 240, 300, 360(Two Compressor)8

Cabinet ConfigurationB – Bottom Discharge/Return1

S – Side Discharge/Return Only (180-360)

Voltage0 – 208-230/60/1 (036-072 Only) 3 – 208-230/60/34 – 460/60/3

Refrigeration Option0 – NoneG – Hot Gas Bypass R – Hot Gas Reheat B – Hot Gas Reheat w/Hot Gas Bypass

Blower Options 1 – Variable Speed ECM, Forward Curve (036-072)10

4 – 5 Speed ECM (036-072)9, 10

5 – Variable Speed ECM-Backward Inclined, High Static1

Water Coil OptionD – Copper, InsulatedP – CuproNickel, Insulated

Sound Kit OptionA – NoneB – Sound Kit

Water Control OptionN – NoneF – Flow Meter2 (036-144) R – Water Flow Regulator (036-072) V – 2 – Way Valve

M – 2 – Way Modulating Valve2

B – 2 – Way Valve w/ Flow Regulator (036-072)

10 11 12 14-16UR S 036 B 0 0 5 D A N 000

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Notes:1 – Field convertible from bottom to side discharge & return (036-144)2 – Only available when used with Aurora Advanced control option3 – Only available when used with UPC DDC control option4 – Must be used with at least one differential enthalpy economizer5 – Only available when used with bottom return configuration.6 – GFI outlet is field wired7 – 208-230/60/1 Only8 – Compressor Lead/Lag only available with UPC9 – Not available with economizer10 – Bottom flow discharge configuration only

VoltageSingle Speed Compressor Dual Capacity Compressor

036 048 060 070 038 049 064 072208-230/60/1 ● ● ● ● ● ● ● ●208-230/60/3 ● ● ● ● ● ● ● ●

460/60/3 ● ● ● ● ● ● ● ●575/60/3

7/27/17

VoltageTwo Compressor

096 120 144 180 181 240 300 360208-230/60/1208-230/60/3 ● ● ● ● ● ● ● ●

460/60/3 ● ● ● ● ● ● ● ●575/60/3

7/27/17

● - Available

5


Curb Nomenclatures

6


Typical Unit InstallationRigging the Unit

A rigging illustration and center-of-gravity dimensional data

table are shown in this manual. Rigging is typically through

a clevis (shackle) attached to each of the four cabinets

corners (six on models 180-360) and then employing a

lifting bar (spanner) to protect the unit. The unit is then set

directly on the curb.

Unit Location and Mounting

If the unit is installed at ground level (horizontal discharge design), elevate it above the snow line. Provide concrete footings at each support location with a full perimeter support structure or a slab foundation for support (mounting on a curb can be used). The unit’s operating and corner loading weights when constructing a footing foundation. If anchoring is required, anchor the unit to the slab using hold down bolts or isolators. To minimize the transmission of vibrations into the building, install isolators. For rooftop applications, ensure the roof is strong enough to support the combined unit and support structural weight.

Duct WorkWhen attaching the duct work to the unit, provide a watertight flexible connector at the unit to prevent

operating sounds from transmitting through the ductwork. Elbows with turning vanes or splitters are recommended to minimize air noise due to turbulence and to reduce static pressure. All outdoor ductwork between the unit and the structure should be weather proofed after installation is complete. See dimensional data for connection sizes.

Roof Curbs

The roof curbs consist of a full perimeter enclosure to sup-port the unit. Before installing any roof curb, verify that the correct roof curb is applied to the unit and that the roof curb includes the necessary gaskets and hardware. Also verify that the proposed installation location provides the required clearance for proper unit operation and ensure that the curb is level and square. The top surface of the curb must be true to assure an adequate curb-to-unit seal. Step-by-step curb assembly and installation instructions ship with each accessory roof curb kit. Follow the instructions carefully to assure proper fit-up when the unit is set into place. To assure proper condensate flow during operation, the unit (and curb) must be level. If the unit is elevated, a field constructed catwalk around the unit is strongly recom-mended to provide easy access for unit maintenance and service. Recommendations for installing the supply air and return air ductwork joining the roof curb are included in the curb instruction booklet.

Installation Notes

7


Horizontal Discharge/Return Conversion

Units are factory shipped in the downflow discharge

configuration, but can be field converted to a horizontal

discharge configuration (036-144, plenum fan only). To

convert remove the side panel covers of the discharge and

return opening and seal provided panels.

Water Piping

All piping access is within the curb in the compressor

section. Piping is usually designed as ‘reverse return’ to

equalize flow paths through each unit. A short flexible

pressure rated hose is used to make connection to the

fixed building piping system. This hose is typically stainless

steel braid and includes a swivel fitting on one end for easy

removal and is flexible to help isolate the unit for quieter

operation. Isolation valves for servicing, y-strainers for

filtering and memory-stop flow valve or a balancing valve

can be provided for consistent water flow through the unit.

All unit source water connections are fittings that accept

a male pipe thread (MPT). Insert the connectors by hand,

then tighten the fitting with a wrench to provide a

leakproof joint. The open and closed loop piping

system should include pressure/temperature ports for

serviceability. The proper water flow must be provided to

each unit whenever the unit operates. To assure proper

flow, use pressure/ temperature ports to determine the

flow rate. These ports should be located at the supply

and return water connections on the unit. The proper

flow rate cannot be accurately set without measuring the

water pressure drop through the refrigerant-to-water heat

exchanger. Never use flexible hoses smaller than the inside

diameter of the water connection at the unit. Limit hose

length to 10 feet per connection. Check carefully for water

leaks.

Installing the Unit

Remove and discard the compressor hold down shipping

bolt located at the front of the compressor mounting

bracket prior to setting the unit in place. All piping and

electric connections are ‘thru the curb’. Follow installation

manual detailed notes.

Installation Notes cont.

8


Acoustical Considerations and Equipment Sound Performance

Sound Performance

The Versatec Packaged Rooftop is third party sound

rated in accordance with ARI WSHP 260. Please consult

WaterFurnace Sound Performance Data Catalog for details

on the AHRI standard and sound performance data.

Recommendations for Noise Reduction

Unit Location• Specify equipment with quietest sound power ratings

• Do not locate units above areas with a required NC 40

or less

• Space WSHP at least 10 ft (3m) apart to avoid noise

summing of multiple units in a space.

Ductwork• Ensure return air grilles will not allow line of site noise to

transfer to adjacent space. Use a sound barrier or some

other material to isolate the grille from the unit. A supply

grille, boot and short piece of flex duct pointed away

from the unit can greatly attenuate equipment noise.

• Use a canvas isolation duct connector at the supply and

return duct connection of the unit.

• Internally line the discharge and return duct within the

first 4-8 feet of unit with acoustic insulation. Install an

internally lined ‘L’ shaped return duct elbow at return

grille. Face the elbow away from adjacent units.

• Always install at least one 90° elbow in the discharge duct

to eliminate line of sight noise transmission of the blower.

• Use turning vanes at all elbows and tees to

reduce turbulence.

• Limit supply duct velocities to less than 1,000 fpm

• Design and install ductwork as stiff as possible

• Allow 3 duct diameters both up and down stream of the

unit before any fittings or transitions are installed.

• Use duct sealant on all duct joints.

• Install a short (2-4’) of flex duct on all branch ducts just

prior to discharge boot or diffuser to reduce vibration

and duct sound prior to delivery in the room.

• Locate the branch duct balancing damper as far away

from the diffuser as possible.

• In ceiling plenum systems, install an internally lined ‘L’

shaped return duct elbow at unit. Face the elbow away

from adjacent units (horizontal).

Installation Notes cont.

9


Dim

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Data

03

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72

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Pan

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CM

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el

BP

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10


Dim

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Data

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09

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Air

SA

=

Sup

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Air

CB

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Pan

el

CM

P =

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Acc

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11


Dim

en

sio

nal

Data

co

nt.

180

-36

0

180

- 360

DIM

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L DA

TA

ISO

VIE

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SS

CB

BP

RA*

SA*

CM

P

CM

P

CM

P

CM

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WAT

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RA*

SA*

RA

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SA

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Air

CB

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12


Dimensional Data cont.

Electrical/Water

WATER IN/OUT ENTRY

HV/LV POWER ENTRY

WATER IN/OUT ENTRY

HV/LV POWER ENTRY

WATER IN/OUT ENTRY

HV/LV POWER ENTRY

13



NAIL(ALL AROUND)

COUNTER FLASHING(FIELD SUPPLIED)

ROOFING MATERIAL(FIELD SUPPLIED)

CANT STRIP(FIELD SUPPLIED)

RIGID INSULATION(FIELD SUPPLIED)

GASKET(SUPPLIED WITH CURB)

UNIT

DUCT(FIELD SUPPLIED)

ROOFING FELT(FIELD SUPPLIED)

Curb Installation

14



036-144 Curb

15


S


036-144 Curb cont.

16



180-360 Curb

3/4" FLANGES(TYP FOR BOTH DUCTS)

Front/Back RailLeft/Right Rail

Front/Back Rail

Left/Right Rail

180-360 CURB

17



180-360 Curb cont.

RETURN

SUPPLY

Front/Back Rail

Left/Right Rail

18


C C

SECTION C-C

RETURN AIR DUCT

SUPPLY AIR DUCT


Curb cont.

19


NTING

1 1/2 x 1/4 P.V.C. GASKET

RLAP AND POSITION JOINTS IN P.V.C.R GASKETEALS - APPLY P.V.C. RUBBER LAST TOTHERE IS ADEQUATE P.V.C. FOR THESEAL.

TYPICAL SEALING METHODS TO PREVENTCT LEAKAGE AT CURB-DUCT JOINT.

GASKET SEAL

1 1/2 x 1/4 P.V.C. GASKET


Curb cont.

ROOF MOUNTINGCURB

NOTES;1. OVERLAP AND POSITION JOINTS IN P.V.C.RUBBER GASKET2. AIR SEALS - APPLY P.V.C. RUBBER LAST TOINSURE THERE IS ADEQUATE P.V.C. FOR THEWATER SEAL.3. USE TYPICAL SEALING METHODS TO PREVENTAIR DUCT LEAKAGE AT CURB-DUCT JOINT.

20


Center of Gravity and Weights

Center of Gravity

Unit 036-072 096-144 180-360

E 21 40 47

F 32 28 51

10/05/2017

Rooftop Weights (with Economizer)

Accessory Options Weights

ModelNet/Shipping

Weight036-038 850048-049 880060-064 900070-072 910

096 1580120 1590144 1620180 3250181 3380240 3460300 3465360 3540

12/06/17

Accessory/Option Weights (lbs. [kg])

036-072 096-144 180-360

Economizer 123 165 267Motorized Damper 20 30 50Barometric Damper 7 10 15

10/05/2017

E

F

C D

BA

21


Lifting

A

DETAIL A

USE SPREADER BARSTO PREVENT DAMAGEOF UNIT

ATTACH CHAIN ORCABLE TO SHACKLE

Minimum Spanner Width

ModelMin.

Spanner Width

in. [cm]036-072 40 [101.6]096-144 52 [132.4]180-360 82 [208.3]

7/31/2017

22


Condensate Drain

DETAIL D DETAIL EP+1

P/2

3/4" NPT Pipe Size, 14 Threads Per Inch,0.55" Threaded Engagement

036-360 Condensate

In ground water situations where scaling could be heavy

or where biological growth such as iron bacteria will be

present, a closed loop system is recommended. The heat

exchanger coils in ground water systems may, over a period

of time, lose heat exchange capabilities due to a buildup

of mineral deposits inside. These can be cleaned, but only

by a qualified service mechanic, as special solutions and

pumping equipment are required. Hot water generator coils

can likewise become scaled and possibly plugged. In areas

Water Quality

Material Copper 90/10 Cupronickel 316 Stainless SteelpH Acidity/Alkalinity 7 - 9 7 - 9 7 - 9

ScalingCalcium and

Magnesium Carbonate(Total Hardness)

less than 350 ppm(Total Hardness)

less than 350 ppm(Total Hardness)

less than 350 ppm

Corrosion

Hydrogen SulfideLess than 0.5 ppm (rotten egg

smell appears at 0.5 ppm)10 - 50 ppm Less than 1 ppm

Sulfates Less than 125 ppm Less than 125 ppm Less than 200 ppm

Chlorine Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Chlorides Less than 20 ppm Less than 125 ppm Less than 300 ppm

Carbon Dioxide Less than 50 ppm 10 - 50 ppm 10 - 50 ppm

Ammonia Less than 2 ppm Less than 2 ppm Less than 20 ppm

Ammonia Chloride Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Nitrate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Hydroxide Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Sulfate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Total Dissolved Solids (TDS) Less than 1000 ppm 1000 - 1500 ppm 1000 - 1500 ppm

LSI Index +0.5 to -0.5 +0.5 to -0.5 +0.5 to -0.5

Iron Fouling(Biological Growth)

Iron, FE2+ (Ferrous)Bacterial Iron Potential

< 0.2 ppm < 0.2 ppm < 0.2 ppm

Iron OxideLess than 1 ppm, above this level deposition will occur

Less than 1 ppm, above this level deposition will occur

Less than 1 ppm, above this level deposition will occur

ErosionSuspended Solids

Less than 10 ppm and filtered for max. of 600 micron size



Threshold Velocity(Fresh Water)

< 6 ft/sec < 6 ft/sec < 6 ft/sec

NOTES: Grains = ppm divided by 17 mg/L is equivalent to ppm

2/22/12

with extremely hard water, the owner should be informed

that the heat exchanger may require occasional flushing.

Failure to adhere to the guidelines in the water quality table

could result in loss of warranty.

Units with cupronickel heat exchangers are recommended

for open loop applications due to the increased resistance

to build-up and corrosion, along with reduced wear caused

by acid cleaning.

The internal condensate drain assembly consists of a stainless steel drain tube which is connected to a stainless steel drain

pan. The drain pan is installed in the equipment so that it is sloping in multiple directions to ensure the drain tube is at the

lowest point to promote proper drainage. The drains are not internally trapped therefore this must be done in the field.

23


System Cleaning and Flushing

Cleaning and FlushingPrior to start up of any heat pump, the water circulating system must be cleaned and flushed of all dirt and debris.

If the system is equipped with water shutoff valves, the supply and return runouts must be connected together at each unit location (This will prevent the introduction of dirt into the unit, see Flushing with Water Shutoff Valve Equipped Systems illustration). The system should be filled at the water make-up connection with all air vents open. After filling, vents should be closed.

The contractor should start the main circulator with the pressure reducing valve makeup open. Vents should be checked in sequence to bleed off any trapped air and to verify circulation through all components of the system.

As water circulates through the system, the contractor should check and repair any leaks found in the piping system. Drain(s) at the lowest point(s) in the system should be opened for initial flush and blowdown, making sure water fill valves are set at the same rate. Check the pressure gauge at the pump suction and manually adjust the make-up water valve to hold the same positive pressure both before and after opening the drain valves. Flushing should continue for at least two hours, or longer if required, until drain water is clean and clear.

The supplemental heater and/or circulator pump, if used, should be shut off. All drains and vents should be opened to completely drain the system. Short-circuited supply and return runouts should now be connected to the unit supply and return connections.

Refill the system with clean water. Test the system water for acidity and treat as required to leave the water slightly alkaline (pH 7.5 to 8.5). The specified percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVAC systems only. Environol™ brand antifreeze is recommended.

Once the system has been filled with clean water and antifreeze (if used), precautions should be taken to protect the system from dirty water conditions. Dirty water will result in system-wide degradation of performance, and solids may clog valves, strainers, flow regulators, etc. Additionally, the heat exchanger may become clogged which reduces compressor service life and can cause premature unit failure.

In boiler/tower application, set the loop control panel set points to desired temperatures. Supply power to all motors and start the circulating pumps. After full flow has been established through all components including the heat rejector (regardless of season), air vented and loop

temperatures stabilized, each of the units will be ready for

check, test and start up and for air and water balancing.

Return Runout

Supply Runout

Mains

Rubber Hose

Runouts InitiallyConnected Together

Flushing with Water Shutoff Valve Equipped Systems

Ground Source Loop System CheckoutOnce piping is completed between the unit pumping system

and ground loop, final purging and charging of the loop is

needed. A high pressure pump is needed to achieve adequate

flow velocity in the loop to purge air and dirt particles from

the loop itself. Antifreeze solution is used in most areas to

prevent freezing. Flush the system adequately to remove

as much air as possible; then pressurize the loop to a static

pressure of 40-50 PSI (summer) or 50-75 PSI (winter). This

is normally adequate for good system operation. Loop static

pressure may decrease soon after initial installation, due

to pipe expansion and loop temperature change. Running

the unit for at least 30 minutes after the system has been

completely purged of air will allow for the “break-in” period.

It may be necessary to adjust static loop pressure (by adding

water) after the unit has run for the first time. Loop static

pressure will also fluctuate with the seasons. Pressures

will be higher in the winter months than during the cooling

season. This fluctuation is normal and should be considered

when charging the system initially.

Ensure the pump provides adequate flow through the unit by

checking pressure drop across the heat exchanger.

Usually 2.25-3.0 gpm of flow per ton of cooling capacity is

recommended in earth loop applications.

24


208 Volt OperationAll 208/230 units are factory wired for 230 volt operation.

For 208 volt operation, the red and blue transformer wires

must be switched on terminal strip PS.

CAUTION: When installing a unit with a forward curve, variable speed ECM blower motor in 460/60/3 voltage, a neutral wire is required to allow proper unit operation.

Each compressor is equipped with a crankcase heater that

is controlled through a relay so that the heater is only op-

erational when the compressor is off. The crankcase heater

warms the oil temperature in the compressor to prevent

liquid refrigerant migration back into the compressor where

it could condense and mix with oil. This can cause a num-

ber of problems such as lack of lubrication on bearings and

therefore lead to mechanical failure of the compressor.

GeneralBe sure the available power is the same voltage and phase

as that shown on the unit serial plate. Line and low voltage

wiring must be done in accordance with local codes or the

National Electric Code, whichever is applicable.

Power ConnectionConnect the incoming line voltage wires to L1 and L2 of the

contactor for single-phase unit. Consult the Electrical Data

tables for correct fuse sizes.

Electrical Connections

Compressor Crankcase Heaters

For Aurora Base Control, set SW2-1, FP1, on the printed

circuit board for applications using a closed loop antifreeze

solution to 15°F [-9.4°C]. On applications using an open

loop/ground water system (or closed loop no antifreeze), set

this dip switch to 30°F [-1.1°C], the factory default setting.

(Refer to the Dip Switch Field Selection table).

Freeze Detection

Aurora Base Control Box

25


Electrical Data

3-6 ton 5-Speed ECM Fan

Model Rated VoltageVoltage Min/Max

Compressor BlowerMotorFLA

TotalUnitFLA

MinCircAmp

MaxFuse/HACR

BreakerMCC RLA LRA LRA**

Sin

gle

Sp

ee

d

Co

mp

ress

or

- 5

Sp

d

036208-230/60/1 187/253 22.0 14.1 73.0 29.2 4.1 18.2 21.7 35208-230/60/3 187/253 13.9 8.9 58.0 34.8 4.1 13.0 15.2 20

460/60/3 414/506 6.5 4.2 28.0 16.8 2.1 6.3 7.4 10/15

048208-230/60/1 187/253 31.0 19.9 109.0 43.6 7.6 27.5 32.5 50208-230/60/3 187/253 21.2 13.6 83.1 49.9 7.6 21.2 24.6 35

460/60/3 414/506 9.5 6.1 41.0 24.6 4.0 10.1 11.6 15

060208-230/60/1 187/253 41.2 26.4 134.0 53.6 7.6 34.0 40.6 60208-230/60/3 187/253 24.9 16.0 110.0 66.0 7.6 23.6 27.6 40

460/60/3 414/506 12.1 7.8 52.0 31.2 4.0 11.8 13.8 20

070208-230/60/1 187/253 44.2 28.3 178.0 71.2 7.6 35.9 43.0 70208-230/60/3 187/253 30.0 19.2 136.0 81.6 7.6 26.8 31.6 50

460/60/3 414/506 13.6 8.7 66.1 39.7 4.0 12.7 14.9 20

Du

al

Cap

acit

y

Co

mp

ress

or

- 5

Sp

d

038208-230/60/1 187/253 23.8 15.3 83.0 33.2 4.1 19.4 23.2 35208-230/60/3 187/253 18.1 11.6 73.0 43.8 4.1 15.7 18.6 30

460/60/3 414/506 8.9 5.7 38.0 22.8 2.1 7.8 9.2 10/15

049208-230/60/1 187/253 33.0 21.1 104.0 41.6 7.6 28.7 34.0 50208-230/60/3 187/253 21.9 14.0 83.1 49.9 7.6 21.6 25.1 35

460/60/3 414/506 10.0 6.4 41.0 24.6 4.0 10.4 12.0 15

064208-230/60/1 187/253 42.3 27.1 152.9 61.2 7.6 34.7 41.5 60208-230/60/3 187/253 25.8 16.5 110.0 66.0 7.6 24.1 28.2 40

460/60/3 414/506 11.3 7.2 52.0 31.2 4.0 11.2 13.0 20

072208-230/60/1 187/253 46.3 29.7 179.2 71.7 7.6 37.3 44.7 70208-230/60/3 187/253 27.4 17.6 136.0 81.6 7.6 25.2 29.6 45

460/60/3 414/506 13.2 8.5 66.1 39.7 4.0 12.5 14.6 20

Sin

gle

Sp

ee

d C

om

pre

sso

r

EC

M F

an

036208-230/60/1 187/253 22.0 14.1 73.0 29.2 7.0 21.1 24.6 35208-230/60/3 187/253 13.9 8.9 58.0 34.8 7.0 15.9 18.1 25

460/60/3 414/506 6.5 4.2 28.0 16.8 6.9 11.1 12.2 15

048208-230/60/1 187/253 31.0 19.9 109.0 43.6 7.0 26.9 31.9 50208-230/60/3 187/253 21.2 13.6 83.1 49.9 7.0 20.6 24.0 35

460/60/3 414/506 9.5 6.1 41.0 24.6 6.9 13.0 14.5 20

060208-230/60/1 187/253 41.2 26.4 134.0 53.6 7.0 33.4 40.0 60208-230/60/3 187/253 24.9 16.0 110.0 66.0 7.0 23.0 27.0 40

460/60/3 414/506 12.1 7.8 52.0 31.2 6.9 14.7 16.7 20

070208-230/60/1 187/253 44.2 28.3 178.0 71.2 7.0 35.3 42.4 70208-230/60/3 187/253 30.0 19.2 136.0 81.6 7.0 26.2 31.0 50

460/60/3 414/506 13.6 8.7 66.1 39.7 6.9 15.6 17.8 25

Du

al

Cap

acit

y C

om

pre

sso

r

EC

M F

an

038208-230/60/1 187/253 23.8 15.3 83.0 33.2 7.0 22.3 26.1 40208-230/60/3 187/253 18.1 11.6 73.0 43.8 7.0 18.6 21.5 30

460/60/3 414/506 8.9 5.7 38.0 22.8 6.9 12.6 14.0 15

049208-230/60/1 187/253 33.0 21.1 104.0 41.6 7.0 28.1 33.4 50208-230/60/3 187/253 21.9 14.0 83.1 49.9 7.0 21.0 24.5 35

460/60/3 414/506 10.0 6.4 41.0 24.6 6.9 13.3 14.9 20

064208-230/60/1 187/253 42.3 27.1 152.9 61.2 7.0 34.1 40.9 60208-230/60/3 187/253 25.8 16.5 110.0 66.0 7.0 23.5 27.6 40

460/60/3 414/506 11.3 7.2 52.0 31.2 6.9 14.1 15.9 20

072208-230/60/1 187/253 46.3 29.7 179.2 71.7 7.0 36.7 44.1 70208-230/60/3 187/253 27.4 17.6 136.0 81.6 7.0 24.6 29.0 45

460/60/3 414/506 13.2 8.5 66.1 39.7 6.9 15.4 17.5 25

HACR circuit breaker in USA only 07/28/2017**With optional IntelliStart (single phase only)

26


Electrical Data cont.

3-30 Ton Plenum Fan

ModelRated

VoltageVoltage Min/Max

Compressor (each) BlowerMotor (each)

FLA

TotalUnitFLA

MinCircAmp

MaxFuse/HACR

BreakerMCC RLA LRA LRA**

Sin

gle

Sp

ee

d C

om

pre

sso

r

P

len

um

Fan

036

208-230/60/1 187/253 22.0 14.1 73.0 29.2 4.9 19.0 22.5 35

208-230/60/3 187/253 13.9 8.9 58.0 34.8 4.9 13.8 16.0 20

460/60/3 414/506 6.5 4.2 28.0 16.8 2.9 7.1 8.1 10/15

048

208-230/60/1 187/253 31.0 19.9 109.0 43.6 4.9 24.8 29.8 45

208-230/60/3 187/253 21.2 13.6 83.1 49.9 4.9 18.5 21.9 35

460/60/3 414/506 9.5 6.1 41.0 24.6 2.9 8.9 10.5 15

060

208-230/60/1 187/253 41.2 26.4 134.0 53.6 4.9 31.3 37.9 60

208-230/60/3 187/253 24.9 16.0 110.0 66.0 4.9 20.9 24.9 40

460/60/3 414/506 12.1 7.8 52.0 31.2 3.2 11.0 13.0 20

070

208-230/60/1 187/253 44.2 28.3 178.0 71.2 4.9 33.2 40.3 60

208-230/60/3 187/253 30.0 19.2 136.0 81.6 4.9 24.1 28.9 45

460/60/3 414/506 13.6 8.7 66.1 39.7 3.2 11.9 14.1 20

Du

al

Cap

acit

y C

om

pre

sso

r

P

len

um

Fan

038

208-230/60/1 187/253 23.8 15.3 83.0 33.2 4.9 20.2 24.0 35

208-230/60/3 187/253 18.1 11.6 73.0 43.8 4.9 16.5 19.4 30

460/60/3 414/506 8.9 5.7 38.0 22.8 2.9 8.6 10.0 15

049

208-230/60/1 187/253 33.0 21.1 104.0 41.6 4.9 26.0 31.3 50

208-230/60/3 187/253 21.9 14.0 83.1 49.9 4.9 18.9 22.4 35

460/60/3 414/506 10.0 6.4 41.0 24.6 2.9 9.3 10.9 15

064

208-230/60/1 187/253 42.3 27.1 152.9 61.2 4.9 32.0 38.8 60

208-230/60/3 187/253 25.8 16.5 110.0 66.0 4.9 21.4 25.5 40

460/60/3 414/506 11.3 7.2 52.0 31.2 3.2 10.4 12.2 15

072

208-230/60/1 187/253 46.3 29.7 179.2 71.7 4.9 34.6 42.0 70

208-230/60/3 187/253 27.4 17.6 136.0 81.6 4.9 22.5 26.9 40

460/60/3 414/506 13.2 8.5 66.1 39.7 3.2 11.7 13.8 20

Tw

o C

om

pre

sso

rs &

P

len

um

Fan

096208-230/60/3 187/253 21.2 15.1 83.1 NA 9.2 39.4 43.2 50

460/60/3 414/506 9.5 6.8 41.0 NA 6.8 20.4 22.1 25

120208-230/60/3 187/253 24.9 15.9 110.0 NA 9.2 41.0 45.0 60

460/60/3 414/506 12.1 7.7 52.0 NA 6.8 22.2 24.1 30

144208-230/60/3 187/253 30.0 21.4 136.0 NA 9.2 52.0 57.4 75

460/60/3 414/506 13.6 9.7 66.4 NA 6.8 26.2 28.6 35

180208-230/60/3 187/253 36.2 23.2 164.0 NA 9.2 55.6 61.4 80

460/60/3 414/506 17.5 11.2 75.0 NA 6.8 29.2 32.0 40

Tw

o C

om

pre

sso

rs &

Tw

o P

len

um

Fan

s 181208-230/60/3 187/253 36.2 23.2 164.0 NA 9.2 64.8 70.6 90

460/60/3 414/506 17.5 11.2 75.0 NA 6.8 36.0 38.8 50

240208-230/60/3 187/253 44.0 28.2 240.0 NA 9.2 74.8 81.9 110

460/60/3 414/506 23.0 14.7 130.0 NA 6.8 43.0 46.7 60

300208-230/60/3 187/253 53.0 34.0 240.0 NA 9.2 86.4 94.9 125

460/60/3 414/506 25.0 16.0 140.0 NA 6.8 45.6 49.6 70

360208-230/60/3 187/253 87.0 55.8 340.0 NA 9.2 130.0 144.0 150

460/60/3 414/506 42.0 26.9 173.0 NA 6.8 67.4 74.1 90

HACR circuit breaker in USA only 10/14/2016*With optional high Static Fan**With optional IntelliStart

27


Blower Performance Data

Rooftop Series Single Speed

5 Speed ECM Blower Performance

Rooftop Series Dual Capacity

28


Blower Performance Data cont.

Variable Speed ECM Blower Performance

Rooftop Single Speed

Rooftop Dual Capacity

29


Blower Performance Data cont.Integrated EC Backward Curved Plenum Fan PerformanceModel 036-038

Model 048-049

30



Model 070-072

Model 060-064

31



Model 120

Model 096

32



Model 144 (High Static)

Model 144

33



Model 181 (High Static)

Model 180

34


Model 300

Model 240


35


Blower Performance Data cont.Model 360

36


The ABC board’s Yellow Confi g LED will fl ash the current variable speed ECM blower speed selections for low, med, and high continuously with a short pause in between. The speeds can also be confi rmed with the AID Tool under the Setup/ECM Setup screen. The variable speed ECM blower motor speeds can be fi eld adjusted with or without using an AID Tool.

Variable Speed ECM Setup without an AID ToolThe blower speeds for Low (G only), Med (Y1), and High (Y2/Aux) can be adjusted directly at the Aurora ABC board which utilizes the push button (SW1) on the ABC board. This procedure is outlined in the Variable Speed ECM Confi guration Mode portion of the Aurora ‘Base’

Control System section.

Variable Speed ECM Setup with an AID ToolA much easier method utilizes the AID Tool to change the airfl ow using the procedure below. First navigate to the Setup screen and then select ECM Setup. This screen displays the current variable speed ECM settings. It allows the technician to enter the setup screens to change the variable speed ECM settings. Change the highlighted item using the ◄ and ► buttons and then press the ◙ button to select the item.

Setting Blower Speed - Variable Speed ECM

Variable Speed ECM Speed Setup - These screens allow the technician to select the low, medium, and high blower speed for the variable speed ECM blower motor. Change the highlighted item using the ▲ and ▼ buttons. Press the ◙

button to select the speed.

After the high speed setting is selected the AID Tool will

automatically transfer back to the ECM Setup screen.

Variable Speed ECM Setup with an AID Tool cont.Selecting YES will enter variable speed ECM speed setup, while selecting NO will return to the previous screen.

ECM SPEED INFO

LOW SPEED: 3MED SPEED: 5HIGH SPEED: 7

WANT TO CHANGE?

YESOPTION ◄►

NOENTER ◙

ECM SPEED INFO

12 <– LOW3456789101112

OPTION ◄► ENTER ◙

ECM SPEED INFO

12 LOW345 <– MED6789101112


ECM SPEED INFO

12 LOW345 MED6789101112 <– HIGH



37


Typical Schematic Examples

Schematic VoltageFan Type

(Qty)Compressor

QtyIntelliStart

Motorized Damper

Economizer Aurora Controls DDC

A 208-230/60/1 5 spd ECM 1 - Optional L Base/Advanced LB 208-230/60/1 5 spd ECM 1 Yes Optional L Base/Advanced LC 208-230/60/1 VS ECM 1 - Optional L Base/Advanced LD 208-230/60/1 VS ECM 1 Yes Optional L Base/Advanced LE 208-230/60/1 Plenum (1) 1 - Optional L Base/Advanced LF 208-230/60/1 Plenum (1) 1 Yes Optional L Base/Advanced LG 208-230-460/60/3 5 spd ECM 1 - Optional L Base/Advanced LH 208-230/60/3 VS ECM 1 - Optional L Base/Advanced LI 460/60/3 VS ECM 1 - Optional L Base/Advanced LJ 208-230-460/60/3 Plenum (1) 1 - Optional L Base/Advanced LK 208-230-460/60/3 Plenum (2) 2 - Optional L Base L

K+L 208-230-460/60/3 Plenum (2) 2 - Optional L Advanced LM - - - - - Optional - YesN 208-230-460/60/3 Plenum (2) 2 - - - - -

8/3/17

38


CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On

Reheat/NormalL Output Type

CC – Dual/SingleAcc – Dip 5Acc – Dip 4

RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678

ALMALGACC COMACC NOACC NC

RC

GY1

EH2CEH1CCOC R - +C R - +

Off

Faul tLED1

R

StatusLED3

ConfigLED2

CC2 CC F C R F FG CC CCGCC2HI

CC2LO

CC2G REVREVFP1 FP1 FP2 FP2 LPS LPSHPSHPS

Aurora Base Control A(ABC-A)

K1-RV Relay

K2-CC Relay

K3-CC2 Relay

K4-Fan RelayK5-Alarm Relay

K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Violet (18)

Black (19)

Yellow (17)

CondensateBrown (30)

(Note 1)

PB1

2

1

3

Gree

n/Ye

llow

(15)

CCA

Outdoor Air Damper

To UPC

ValveWater Valve

CCHR

Red

RedBlack

RV

HPLP

T

FP1RV

T

FP2

Dual Capacity Units Only

RCP

CS

See Note 3

Black (21)Violet (20)

Blue (22)Blue (23)

BlueBlue

Black

Red

Reheat Valve

Black/White

UltraTech

Brown (31)

Orange (1)

Orange (2)

Yellow (3)

Yellow (4)

Black

Black

Blue (7)

Blue (8)

Black (9)

Black (10)

Black/White (16)

HW

P8

MOTOR

P6

RS485

P7

ZONE

P9

ABC

STEPPER ANA ACC2 DH DIV

NOCOM

K6

NOCOM

K5

C

R

L1

L1

L2

L2P10 P5 P11

CR(-)(+)

CR(-)(+)

CR(-)(+)

P4 P2

K1K2K3

HA2 HA1 SGILOOP VS DATA VS PUMP PUMP SLAVE

P3

V+CRTXRX

+5

P14LLTP1

LATFLOWLWTEWT

CT24 3

CT24 3

CT12 1

CT12 1

StatusG

DISCHP16

P17 P18 P15

(Aurora Expansion Board)AXB™

SW1

Modbus Add. ID

Future Use12345

ONOFF

Future UseAcc 2 – Dip 1Acc 2 – Dip 2

S +5 C CC2 1 INOUT+5S

SCT2 13

HW12

C

P12SCP

2 13

Heat Shrink

Red

GreenWhite

T

T

T

T

Aurora Advanced Op on

123

LN

G5 Speed ECM Blower Motor

C45

Green

Black

Red

Unit Power Supply

L1 L2

L2L1

G

Non-Fused Di sconnect, HACR Circ ui t Brea ker, or Termina l Block

White (B)Black (A)

Orange

Bro wn

BlackBlueRedGray Tan

Black

Red

Gray

Modula ng Water Valve

32

1

Gray

Red

Black

~

Y

COM

TBlue

Blue

GNDOUT

RedWhite

SU CTI ONPRES SU RE

TRA NSD UCER5DC321Black

Compressor T1

Compressor T2

Blower CTBrown

Red

Red

Blue

Blue

Green/Yellow (14)Black

Red

Black

Economizer Damper

12

34

~

COM

Y

U

12

34

~

COM

Y

U

Black

Red

Orange

Orange

Gray

Orange

Gray

GND

OUT

5DC

123W

hite

DISCHARGEPRESSURE

TRANSDUCER

Black

Red

Brown

Brown

GrayGray

Purple

Purple

White

White

GND

OUT

5DC

324Brow

n

FLOW METER

Green

White

Wiring Schematic - A

Rooftop 036-072 Single/Dual Capacity, 1 Phase, 5-Speed ECM

39


Accessory Relay

Cycle with BlowerCycle with CompressorWater Valve Slow OpenOutdoor Air Damper

SW2-4 SW2-5On OnOff OffOn OffOff On

Operation

Event Normal Mode Test ModeRandom Start DelayCompressor On DelayCompressor Minimum On TimeCompressor Short Cycle DelayBlower Off DelayFaul t Recogn ition Delay – High PressureStart-Up Bypass – Low PressureFaul t Recogn ition Delay – Low PressureStart-Up Bypass – Low Water/Air Coil LimitFaul t Recogn ition Delay – Low Water/Air Coil LimitFaul t Recogn ition Delay – Condensate OverflowThermostat Call Recognition TimeAuxi liary Heat Staging DelayEmergency Heat Staging Delay

Less than 1 second

5 to 80 seconds 1 second5 seconds < 1 second

30 seconds 2 secondsLess than 1 second

2 minutes 5 seconds4 minutes 15 seconds

2 minutes

2 minutes

30 seconds30 seconds 30 seconds

30 seconds30 seconds

30 seconds30 seconds30 seconds

2 seconds 2 seconds5 minutes2 minutes

20 seconds7.5 seconds

Aurora Timing Events

Reheat Delay 30 seconds 30 secondsWater Valve Slow Open Delay 90 seconds 90 seconds

Slow FlashFast FlashFlash Code

Status LED (LED1, Green)Configuration LED (LED2, Yellow)Faul t LED (LED3, Red)

Sta tus LED (LED1, Green)Normal ModeControl is Non-FunctionalTest ModeLockout ActiveDehumidification ModeReservedReservedLoad ShedESD

1 second on and 1 second off

Random Start DelayFast Flash

OFFON

Slow FlashFast Flash

Flash Code 2Flash Code 3

Flash Code 6


Aurora LED Flash Codes

100 milliseconds on and 100 milliseconds off100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating

Reserved Flash Code 7

Configuration LED (LED2, Yellow) Fault LED (LED3, Red)

Fast FlashFast Flash

No Software Overide Flash ECM SettingDIP Switch Overide Slow Flash

Normal ModeInput Fault LockoutHigh Pressure LockoutLow Pressure Lockout

Low Water Coil Limi t Lockout - FP1Low Air Coil Limi t Lockout - FP2

ReservedCondensate Overflow LockoutOver/Under Voltage ShutdownReservedReservedAir/Water Coil Limit Sensor Error

Flash Code 1OFF

Flash Code 2Flash Code 3Flash Code 4Flash Code 5

Flash Code 8


Flash Code 9Flash Code 10Flash Code 11

ECM Configu re Mode Fast FlashReset Configure Mode Off

CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status

AURORA BASE CONTROL™

RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc

O/BCRLO G Y1 Y2 W DH

3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory

Factory Fan Connection

R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF

RV – B/OACC – Dip 4

ACC – Dip 5CC – Dual/Single

L – Pulse/Continuous

Reheat/Normal

Fact

ory U

se

Field ConnectionsField Connections

C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

Page 1

97P912-01 07/26/17

24V

Transformer

Green/Yellow (29)Control Box Base Panel

Control Box Door

Clas

s 2

Notes:1 – P1 (screw terminals) and P9 (Molex connector) are adjacent and share common terminals in the same order.

2 – Optional isolation or reheat valve. If valve is not present, wires are not connected and tied off.

3 – See supplemental schematic for AXB and/or UPC connections.

Red for 208VBlue for 230VRed for 460V

Yellow

CCH

CCHR

CCT2 T1

Compressor

C

R

SBlue

L1L2

Tan

Cap Black

Green/Yellow

Red

Black

Black (H)

Black

BlackBlack (J)

Black (K)

Thermistor

Relay Coi l

Switch - Condensate OverflowSwitch - High pressure

Switch - Low pressure

Polarized connector

Factory Low Voltage WiringFactory Line Vol tage WiringField Low Voltage WiringField Line Voltage Wi ringOptional BlockDC Voltage PCB Traces

Internal JunctionQuick Connect Terminal

Field Wiring Lug

Ground

Relay Con tacts – N.O., N.C.

Field Zone Sensor Wi ring

Legend

L1

Capacitor

T

123

CC – Compressor ContactorCO – Condensate Overflow SensorES – Emergency ShutdownEWT – Entering Water Temp SensorHP1 – High Pressure Switch 1HP2 – High Pressure Switch 2LAT – Leaving Ai r TempLLT – Liquid Line TempLP1 – Low Pressure Switch 1LP2 – Low Pressure Switch 2LWT – Leaving Water Temp

FuseLight Emitti ng Diode - GreenG

Light Emitti ng Diode - YellowY

Light Emitti ng Diode - RedR

FP1 – Freeze Protection Sensor 1FP2 – Freeze Protection Sensor 2F1 – FuseSW1 – Push buttonSW2 – DIP package 8 positionRB – Blower RelayRV1 – Reversing Valve Coi l 1RV2 – Reversing Valve Coi l 2PGM – Phase Guard Moni torRH – Reheat Valve Coi l

EX-X

X Pin Number Designation on Twist-Lock Connector

Current Transducer

Wiring Schematics - A (cont.)

Rooftop 036-072 Single/Dual Capacity, 1 Phase, 5-Speed ECM

40


Wiring Schematics - B

Rooftop 036-072 Single Speed/Dual Capacity, 1 phase, 5 Speed ECM, IntelliStart

CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On

Reheat/FutureL Output Type


RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO



K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Violet (18)

Black (19)

Yellow (17)


(Note 1)

PB1

2

1

3

Gree

n/Ye

llow

(15)

CCA

Outdoor Air Damper

To UPC

ValveWater Valve

CCHR

Red

RedBlack

RV

HPLP

T

FP1RV

T

FP2


RCP

CS

See Note 3


Blue (22)Blue (23)

BlueBlue

Black

Red

Reheat Valve

Black/White

UltraTech

Brown (31)

Orange (1)

Orange (2)

Yellow (3)

Yellow (4)

Black

Black

Blue (7)

Blue (8)

Black (9)

Black (10)

Black/White (16)

HW

P8

MOTOR

P6

RS485

P7

ZONE

P9

ABC


NOCOM

K6

NOCOM

K5

C

R

L1

L1

L2

L2P10 P5 P11

CR(-)(+)

CR(-)(+)

CR(-)(+)

P4 P2

K1K2K3


P3

V+CRTXRX

+5

P14LLTP1

LATFLOWLWTEWT

CT24 3

CT24 3

CT12 1

CT12 1

StatusG

DISCHP16

P17 P18 P15


SW1

Modbus Add. ID

Future Use12345

ONOFF



SCT2 13

HW12

C

P12SCP

2 13

Heat Shrink

Red

GreenWhite

T

T

T

T


123

LN

G

5 Speed ECM Blower Motor

C45

Green

Black

Red

Unit Power Supply

L1 L2

L2L1

G


White (B)

Black (A)

Orange

Bro wn

BlackBlueRedGray Tan

Black

Red

Gray


32

1

Gray

Red

Black

~

Y

COM

TBlue

Blue

GNDOUT

RedWhite

5DC321Black

Blower CTBrown

Red

Red

Blue

Blue


Red

Black

Economizer Damper

12

34

~

COM

Y

U

12

34

~

COM

Y

U

Black

Red

Orange

Orange

Gray

Orange

Gray

GND

OUT

5DC

123W

hiteBlack

Red

Brown

Brown

GrayGray

Purple

Purple

White

White

FLOW METER

GND

OUT

5DC

324

Green

Brown

White

DISCHARGEPRESSURE

TRANSDUCER

SU CTI ONPRES SU RE

TRA NSD UCER

Compressor T1

Compressor T2

41


Rooftop 036-072 Single Speed/Dual Capacity, 1 phase, 5 Speed ECM, IntelliStart

Wiring Schematics - B (cont.)

Accessory Relay



Operation


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6







No Software Overide Flash ECM Settin gDIP Switch Overide Slow Flash




Flash Code 1OFF


Flash Code 8




CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF




Reheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

24V

Transformer


Control Box Door

Clas

s 2




Red for 208VBlue for 230V

Yellow

CCH

CCHR

CCT2 T1

Compressor

C

R

SBlue

L1L2

Tan

Cap Black

Green/Yellow

Black

Black (H)

Black

BlackBlack (J)

Black (K)

Run Winding

Active

Start

Common

IntelliStart

Blue

Red

Pink

Black

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123






EX-X


Current Transducer

42


Wiring Schematics - C

Rooftop 036-072 Single Speed/Dual Capacity, 1 Phase, VS ECM

CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On



RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO


Aurora Base Control A(ABC-A)K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Violet (18)

Black (19)

Yellow (17)


(Note 1)

PB1

2

1

3

Gree

n/Ye

llow

(15)

CCA

Outdoor Air Damper

To UPC

CCHR

Red

Black

RV

HPLP

T

FP1RV

T

FP2


RCP

CS

See Note 3


Blue (22)

Blue (23)

BlueBlue

Yellow

Black/White

UltraTech

Brown (31)

Orange (1)

Orange (2)

Yellow (3)

Yellow (4)

Yellow (5)

Yellow (6)

Blue (7)

Blue (8)

Black (9)

Black (10)

ECM2 Fan Mo tor

P12

P112 3 4 51

1 312 15 10

PWM

C1 C2R G

16

CFM

Brown

OrangeGreen

Violet (42)

Blue (24)Yellow (25)

Green/Yellow (28)

Black/White (16)

ValveWater Valve

Red

RedBlack

Black

Red

Reheat Valve

HW

P8

MOTOR

P6

RS485

P7

ZONE

P9

ABC


NOCOM

K6

NOCOM

K5

C

R

L1

L1

L2

L2P10 P5 P11

CR(-)(+)

CR(-)(+)

CR(-)(+)

P4 P2

K1K2K3


P3

V+CRTXRX

+5

P14LLTP1

LATFLOWLWTEWT

CT24 3

CT24 3

CT12 1

CT12 1

StatusG

DISCHP16

P17 P18 P15


SW1

Modbus Add. ID

Future Use12345

ONOFF



SCT2 13

HW12

C

P12SCP

2 13

Heat Shrink

Red

GreenWhite

T

T

T

T FLOW METER



32

1

Gray

Red

Black

~

Y

COM

GND

OUT

5DC

324

Green

White

Brown

Gray

Gray

Brow

n

Brow

n

Purple

Purple

White

White

White

GND

OUT

5DC

123

Black

Red

Green/Yellow (14)

Red

Black

GNDOUT

RedWhite

5DC321Black

TBlue

BlueBlower CT

Brown

Red

Red

Blue

Blue

Orange

Gray

Economizer Damper

12

34

~

COM

Y

U

Gray

12

34

~

COM

Y

U

Black

Red

Orange

Orange

Gray

Black

Red

Black

Red

Compressor T1

Compressor T2

DISCHARGEPRESSURE

TRANSDUCER

SU CTI ONPRES SU RE

TRA NSD UCER

43


Accessory Relay



Operation


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6











Flash Code 1OFF


Flash Code 8




CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF




Reheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

07/27/17

24V

Transformer


Control Box Door

Clas

s 2





Unit Power Supply

L1 L2

L2L1

G


CCH CCHRCCT2 T1

Compressor

C

R

SBlue

L1L2

Tan

Cap Black

Green/Yellow

RedBlack (A)

White (B)

Black (K)

Black (H)

Black

Black

Black (J)

Black

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123






EX-X


Current Transducer

Rooftop 036-072 Single Speed/Dual Capacity, 1 Phase, VS ECM

Wiring Schematics - C (cont.)

44


Wiring Schematics - D

Rooftop 036-072 Single Speed/Dual Capacity, 1 Phase, VS ECM, IntelliStart

CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On



RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO



K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Violet (18)

Black (19)

Yellow (17)


(Note 1)

PB1

2

1

3

Gree

n/Ye

llow

(15)

CCA

Outdoor Air Damper

To UPC

CCHR

Red

Black

RV

HPLP

T

FP1RV

T

FP2


RCP

CS

See Note 3


Blue (22)

Blue (23)

BlueBlue

Yellow

Black/White

UltraTech

Brown (31)

Orange (1)

Orange (2)

Yellow (3)

Yellow (4)

Yellow (5)

Yellow (6)

Blue (7)

Blue (8)

Black (9)

Black (10)

ECM2 Fan Mo tor

P12

P112 3 4 51

1 312 15 10

PWM

C1 C2R G

16

CFM

Brown

OrangeGreen

Violet (42)


Green/Yellow (28)

Black/White (16)

ValveWater Valve

Red

RedBlack

Black

Red

Reheat Valve

HW

P8

MOTOR

P6

RS485

P7

ZONE

P9

ABC


NOCOM

K6

NOCOM

K5

C

R

L1

L1

L2

L2P10 P5 P11

CR(-)(+)

CR(-)(+)

CR(-)(+)

P4 P2

K1K2K3


P3

V+CRTXRX

+5

P14LLTP1

LATFLOWLWTEWT

CT24 3

CT24 3

CT12 1

CT12 1

StatusG

DISCHP16

P17 P18 P15


SW1

Modbus Add. ID

Future Use12345

ONOFF



SCT2 13

HW12

C

P12SCP

2 13

Heat Shrink

Red

GreenWhite

T

T

T

T FLOW METER



32

1

Gray

Red

Black

~

Y

COM

GND

OUT

5DC

324

Green

White

Brown

Gray

Gray

Brow

n

Brow

n

Purple

Purple

White

White

White

GND

OUT

5DC

123

Black

Red

Green/Yellow (14)

Red

Black

GNDOUT

RedWhite

5DC321Black

TBlue

BlueBlower CT

Brown

Red

Red

Blue

Blue

Orange

Gray

Economizer Damper

12

34

~

COM

Y

U

Gray

12

34

~

COM

Y

U

Black

Red

Orange

Orange

Gray

Black

Red

Black

Red

DISCHARGEPRESSURE

TRANSDUCER

SU CTI ONPRES SU RE

TRA NSD UCER

Compressor T1

Compressor T2

45


Rooftop 036-072 Single Speed/Dual Capacity, 1 Phase, VS ECM, IntelliStart

Wiring Schematics - D (cont.)

Accessory Relay



Operation


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6











Flash Code 1OFF


Flash Code 8




CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF




Reheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

24V

Transformer


Control Box Door

Clas

s 2





Unit Power Supply

L1 L2

L2L1

G


CCH CCHRCCT2 T1

Compressor

C

R

SBlue

L1L2

Tan

Cap Black

Green/Yellow

Black (A)

White (B)

Black (K)

Black (H)

Black

Black

Black (J)

Black

Run Winding

Active

Start

Common

IntelliStart

Blue

Red

Pink

Black

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123




Light Emitting Diode - RedR


EX-X


Current Transducer

46


Wiring Schematics - E

Rooftop 036-072 Single Speed/Dual Capacity, 1 Phase, Plenum Fan

CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On



RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO



K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Violet (18)

Black (19)

Yellow (17)


(Note 1)

PB1

2

1

3

Gree

n/Ye

llow

(15)

CCA

Outdoor Air Damper

To UPC

CCHR

Red

Black

RV

HPLP

T

FP1RV

T

FP2


RCP

CS

See Note 3


Blue (22)

Blue (23)

BlueBlue

Black/White

UltraTech

Brown (31)

Orange (1)

Orange (2)

Yellow (3)

Yellow (4)

Yellow (5)

Yellow (6)

Blue (7)

Blue (8)

Black (9)

Black (10)

Black/White (16)

ValveWater Valve

Red

RedBlack

Black

Red

Reheat Valve

HW

P8

MOTOR

P6

RS485

P7

ZONE

P9

ABC


NOCOM

K6

NOCOM

K5

C

R

L1

L1

L2

L2P10 P5 P11

CR(-)(+)

CR(-)(+)

CR(-)(+)

P4 P2

K1K2K3


P3

V+CRTXRX

+5

P14LLTP1

LATFLOWLWTEWT

CT24 3

CT24 3

CT12 1

CT12 1

StatusG

DISCHP16

P17 P18 P15


SW1

Modbus Add. ID

Future Use12345

ONOFF



SCT2 13

HW12

C

P12SCP

2 13

Heat Shrink

Red

GreenWhite



32

1

Gray

Red

Black

~

Y

COM

T

T

T

T

White

Brown

Brown

GrayGray

Purple

Purple

White

White

FLOW METER

GND

OUT

5DC

324

Green

Brown

White

GND

OUT

5DC

123

Black

Red

GNDOUT

RedWhite

5DC321Black

TBlue

Blue


Red

Economizer Damper

12

34

~

COM

Y

U

Black

12

34

~

COM

Y

U

Black

Red

Orange

Orange

Gray

Orange

Gray

Gray

Red

RedBlack

Black

Compressor T1

Compressor T2

DISCHARGEPRESSURE

TRANSDUCER

SU CTI ONPRES SU RE

TRA NSD UCER

Red

Red

Blue

Blue

47



Wiring Schematics - E (cont.)

Accessory Relay



Operation


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6











Flash Code 1OFF


Flash Code 8




CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF




Reheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

24V

Transformer


Control Box Door

Clas

s 2

Notes:1 – P1 (screw terminals) and P9 (Molex connector) are adjacent and share common terminals in the same order.2 – Optional isolation or reheat valve. If valve is not present, wires are not connected and tied off.3 – See supplemental schematic for AXB and/or UPC connections.


Yellow

Black

Unit Power Supply

L1 L2

L2L1

G


CCH CCHRCC

T2 T1

Compressor

C

R

SBlue

L1L2

Tan

Cap Black

Green/Yellow

Red

White (B)

Black (A)

Black (K)

Black (H)

L1 L2

L2L1

Blow

er F

uses

F7 F8

BlowerMotor

L1

L2

White (D)

Black (C)

Black

Black Black (J)

White (F)Black (E)

IDB (D-)

A (D+ )

GN D

IDB (D-)

A (D+ )

GN D

GN Dfo ut

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123


FuseLight Emitting Diode - GreenG

Light Emitting Diode - YellowY



EX-X


Current Transducer

48


Wiring Schematics - F

Rooftop 036-072 Single Speed/Dual Capacity, 1 Phase, Plenum Fan, IntelliStart

CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On



RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO



K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Violet (18)

Black (19)

Yellow (17)


(Note 1)

PB1

2

1

3

Gree

n/Ye

llow

(15)

CCA

Outdoor Air Damper

To UPC

CCHR

Red

Black

RV

HPLP

T

FP1RV

T

FP2


RCP

CS

See Note 3


Blue (22)

Blue (23)

BlueBlue

Black/White

UltraTech

Brown (31)

Orange (1)

Orange (2)

Yellow (3)

Yellow (4)

Yellow (5)

Yellow (6)

Blue (7)

Blue (8)

Black (9)

Black (10)

Black/White (16)

ValveWater Valve

Red

RedBlack

Black

Red

Reheat Valve

HW

P8

MOTOR

P6

RS485

P7

ZONE

P9

ABC


NOCOM

K6

NOCOM

K5

C

R

L1

L1

L2

L2P10 P5 P11

CR(-)(+)

CR(-)(+)

CR(-)(+)

P4 P2

K1K2K3


P3

V+CRTXRX

+5

P14LLTP1

LATFLOWLWTEWT

CT24 3

CT24 3

CT12 1

CT12 1

StatusG

DISCHP16

P17 P18 P15


SW1

Modbus Add. ID

Future Use12345

ONOFF



SCT2 13

HW12

C

P12SCP

2 13

Heat Shrink

Red

GreenWhite



32

1

Gray

Red

Black

~

Y

COM

T

T

T

T

White

Brown

Brown

GrayGray

Purple

Purple

White

White

FLOW METER

GND

OUT

5DC

324

Green

Brown

White

GND

OUT

5DC

123

Black

Red

GNDOUT

RedWhite

5DC321Black

TBlue

Blue


Red

Economizer Damper

12

34

~

COM

Y

U

Black

12

34

~

COM

Y

U

Black

Red

Orange

Orange

Gray

Orange

Gray

Gray

Red

RedBlack

Black

Compressor T1

Compressor T2

DISCHARGEPRESSURE

TRANSDUCER

SU CTI ONPRES SU RE

TRA NSD UCER

Red

Red

Blue

Blue

49


Accessory Relay



Operation


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6







No Software Overide Flash ECM Settin gDIP Switch Overide Slow Flash




Flash Code 1OFF


Flash Code 8




CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF




Reheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

24V

Transformer


Control Box Door

Clas

s 2





Yellow

Black

Unit Power Supply

L1 L2

L2L1

G


CCH CCHRCC

T2 T1

Compressor

C

R

SBlue

L1L2

Tan

Cap Black

Green/Yellow

White (B)

Black (A)

Black (K)

Black (H)

L1 L2

L2L1

Blow

er F

uses

F7 F8

BlowerMotor

L1

L2

White (D)

Black (C)

Black

Black Black (J)

White (F)Black (E)

IDB (D-)

A (D+ )

GN D

IDB (D-)

A (D+ )

GN D

GN Dfo ut

Run Winding

Active

Start

Common

IntelliStartRed

Pink

Black

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123




Light Emitting Diode - RedR


EX-X


Current Transducer

Rooftop 036-072 Single Speed/Dual Capacity, 1 Phase, Plenum Fan, IntelliStart

Wiring Schematics - F (cont.)

50


CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On



RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO



K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Violet (18)

Black (19)

Yellow (17)


(Note 1)

CCA

Outdoor Air Damper

To UPC

ValveWater Valve

CCHR

Red

RedBlack

RV

HPLP

T

FP1RV

T

FP2


RCP

CS

See Note 3


Blue (22)Blue (23)

BlueBlue

Black

Red

Reheat Valve

UltraTech

Brown (31)

Orange (1)

Orange (2)

Yellow (3)

Yellow (4)

Black

Black

Blue (7)

Blue (8)

Black (9)

Black (10)

Black/White (16)

HW

P8

MOTOR

P6

RS485

P7

ZONE

P9

ABC


NOCOM

K6

NOCOM

K5

C

R

L1

L1

L2

L2P10 P5 P11

CR(-)(+)

CR(-)(+)

CR(-)(+)

P4 P2

K1K2K3


P3

V+CRTXRX

+5

P14LLTP1

LATFLOWLWTEWT

CT24 3

CT24 3

CT12 1

CT12 1

StatusG

DISCHP16

P17 P18 P15


SW1

Modbus Add. ID

Future Use12345

ONOFF



SCT2 13

HW12

C

P12SCP

2 13

Heat Shrink

Red

GreenWhite


32

1


Black

Red

Gray

RedBlack

123

LN

G

5 Speed ECM Blower Motor

C45

Green

BlackBlueRed

Gray Tan

~

Y

COM

T

T

T

T

Brown

Brown

Gray

Gray

Purple

Purple

White

White

FLOW METER

GND

OU

T5D

C

324Brow

n

Green

White

GND

OUT

5DC

123W

hiteBlack

Red

TBlue

Blue RedWhite

Black GNDOUT5DC3

21

Black

Gray

Economizer Damper

12

34

~

COM

Y

U

12

34

~

COM

Y

U

Black

Red

Orange

Orange

Gray

Orange

Gray

Compressor A T2

Compressor A T1

Brown

Red

Red

Blue

Blue

Black

Black

Red

Red

DISCHARGEPRESSURE

TRANSDUCER

SU CTI ONPRES SU RE

TRA NSD UCER

Wiring Schematics - G

Rooftop 036-072 Single Speed/Dual Capacity, 3 Phase, 5-Speed ECM

51


Rooftop 036-072 Single Speed/Dual Capacity, 3 Phase, 5-Speed ECM

Wiring Schematics - G (cont.)

Accessory Relay



Operation


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6











Flash Code 1OFF


Flash Code 8




CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF




Reheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

Unit Power Supply

L1 L2 L3

L2L1 L3

GNon-Fused Di sconnect, HACR Circ ui t Brea ker, or Termina l Block

Compressor

CCT1

L1

T2

L2

T3

L3

T1

T2

T3

Green / Yellow

24V

Transformer

Red (T)White (S)

Black (R)


Control Box Door

PB1

2

1

3

Gree

n/Ye

llow

(15)

Clas

s 2

Notes:

CCH CCHRL3L2L1

PhaseGuardMonitor(PGM)

1 – P1 (screw terminals) and P9 (Molex connector) are adjacent and share common terminals in the same order.



PGM

YY-OUT

C

Yellow (12)


Yellow (11)

YellowBlack (13)

Black/White

Black

Blac

k (K)

Whit

e (L)

Red (

M)

Black (N)

Black (P)

Black (Q)

White (B)

Black (A)

Red (C)

Brown

Orange

Black

Black

Green/Yellow (14)

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123






EX-X


Current Transducer

52


Wiring Schematics - H

Rooftop 036-072 Single Speed/Dual Capacity, VS ECM 208-230/60/3

CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On



RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO



K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Violet (18)

Black (19)

Yellow (17)


(Note 1)

CCA

Outdoor Air Damper

To UPC

CCHR

Red

Black

RV

HPLP

T

FP1RV

T

FP2


RCP

CS

See Note 3


Blue (22)

Blue (23)

BlueBlue

UltraTech

Brown (31)

Orange (1)

Orange (2)

Yellow (3)

Yellow (4)

Black

Black

Blue (7)

Blue (8)

Black (9)

Black (10)

ECM2 Fan Mo tor

P12

P112 3 4 51

1 312 15 10

PWM

C1 C2R G

16

CFM

Green

Violet (42)


Green/Yellow (28)

Black/White (16)

HW

P8

MOTOR

P6

RS485

P7

ZONE

P9

ABC


NOCOM

K6

NOCOM

K5

C

R

L1

L1

L2

L2P10 P5 P11

CR(-)(+)

CR(-)(+)

CR(-)(+)

P4 P2

K1K2K3


P3

V+CRTXRX

+5

P14LLTP1

LATFLOWLWTEWT

CT24 3

CT24 3

CT12 1

CT12 1

StatusG

DISCHP16

P17 P18 P15


SW1

Modbus Add. ID

Future Use12345

ONOFF



SCT2 13

HW12

C

P12SCP

2 13

Heat Shrink

Red

Green White

T

T

T

T

Compressor A T2

Compressor A T1

ValveWater Valve Re

d

Red

Blac

k

Black

Red

Reheat Valve

Economizer Damper

Orange

12

34

~

COM

Y

U

Black

Red

Gray



32

1

Gray

Red

Black

~COM

YBlack

Red

GND

OUT

5DC

123W

hite

GNDOUT

RedWhite

PRES SU RE TRANS DUCER5DC3

21Black

Blower CT

12

34

~

COM

Y

U

Black

Red

Orange

Orange

Brown

Red

Red

Blue

Blue

TBlue

Blue

Brown

Brown

Gray

Gray

Purple

Purple

White

White

Gray

Gray

Red

Red

BlackBlack

GND

OUT

5DC

324Brow

n

FLOW METER

Green

White

SU CTI ONPRES SU RE

TRA NSD UCER

DISCHARGEPRESSURE

TRANSDUCER

53


Rooftop 036-072 Single Speed/Dual Capacity, VS ECM 208-230/60/3

Wiring Schematics - H (cont.)

Accessory Relay



Operation


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6











Flash Code 1OFF


Flash Code 8




CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF




Reheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

Unit Power Supply

L1 L2 L3

L2L1 L3


Compressor

CCT1

L1

T2

L2

T3

L3

T1

T2

T3

Green / Yellow

24V

Transformer 1

Red (T) White (S)

Black (R)


Control Box Door

PB1

2

1

3

Gree

n/Ye

llow

(15)

Green/Yellow (14)

Clas

s 2

Notes:

CCH CCHRL3L2L1


1 – P1 (screw terminals) and P9 (Molex connector) are adjacent and share common terminals in the same order.2 – Optional isolation or reheat valve. If valve is not present, wires are not connected and tied off.3 – See supplemental schematic for AXB and/or UPC connections.

PGM

YY-OUT

C

Yellow (12)


Yellow (11)

YellowBlack (13)

Black/White

Black

Blac

k (K)

Whit

e (L)

Red (

M)

Black (N)

Black (P)

Black (Q)

White (B)

Black (A)

Red (C)

Red (C)

Black (A)White (B)

Brown

Orange

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123






EX-X


Current Transducer

54


Wiring Schematics - I

Rooftop 036-072 Single Speed/Dual Capacity, VS ECM 460/60/3

CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On



RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO



K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Violet (18)

Black (19)

Yellow (17)


(Note 1)

CCA

Outdoor Air Damper

To UPC

CCHR

Red

Black

RV

HPLP

T

FP1RV

T

FP2


RCP

CS

See Note 3


Blue (22)

Blue (23)

BlueBlue

UltraTech

Brown (31)

Orange (1)

Orange (2)

Yellow (3)

Yellow (4)

Black

Black

Blue (7)

Blue (8)

Black (9)

Black (10)

ECM2 Fan Mo tor

P12

P112 3 4 51

1 312 15 10

PWM

C1 C2R G

16

CFM

Green

Violet (42)


Green/Yellow (28)

Black/White (16)

HW

P8

MOTOR

P6

RS485

P7

ZONE

P9

ABC


NOCOM

K6

NOCOM

K5

C

R

L1

L1

L2

L2P10 P5 P11

CR(-)(+)

CR(-)(+)

CR(-)(+)

P4 P2

K1K2K3


P3

V+CRTXRX

+5

P14LLTP1

LATFLOWLWTEWT

CT24 3

CT24 3

CT12 1

CT12 1

StatusG

DISCHP16

P17 P18 P15


SW1

Modbus Add. ID

Future Use12345

ONOFF



SCT2 13

HW12

C

P12SCP

2 13

Heat Shrink

Red

Green White

T

T

T

T

Compressor A T2

Compressor A T1

ValveWater Valve Re

d

Red

Blac

k

Black

Red

Reheat Valve

Economizer Damper

Orange

12

34

~

COM

Y

U

Black

Red

Gray



32

1

Gray

Red

Black

~COM

YBlack

Red

GND

OUT

5DC

123W

hite

GNDOUT

RedWhite

5DC321Black

Blower CT

12

34

~

COM

Y

U

Black

Red

Orange

Orange

Brown

Red

Red

Blue

Blue

TBlue

Blue

Brown

Brown

Gray

Gray

Purple

Purple

White

White

Gray

Gray

Red

Red

BlackBlack

GND

OUT

5DC

324Brow

n

FLOW METER

Green

White

DISCHARGEPRESSURE

TRANSDUCER

SU CTI ONPRES SU RE

TRA NSD UCER

55


Wiring Schematics - I (cont.)

Rooftop 036-072 Single Speed/Dual Capacity, VS ECM 460/60/3

Accessory Relay



Operation


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6











Flash Code 1OFF


Flash Code 8




CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF




Reheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

Page 1

Unit Power Supply

L1 L2 L3

L2L1 L3


Compressor

CCT1

L1

T2

L2

T3

L3

T1

T2

T3

Green / Yellow

24V

Transformer 1

Red (T)White (S)

Black (R)


Control Box Door

PB1

2

1

3

Gree

n/Ye

llow

(15)

Green/Yellow (14)

Clas

s 2

Notes:

CCH CCHRL3L2L1



PGM

YY-OUT

C

Yellow (12)


Yellow (11)

YellowBlack (13)

Black/White

Black

Blac

k (K)

Whit

e (L)

Red (

M)

Black (N)

Black (P)

Black (Q)

White (B)

Black (A)

Red (C)

Red (C)

Black (A)White (B)

Brown

Orange

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123




EX-X


N

N



Current Transducer

56


CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On



RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO



K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Violet (18)

Black (19)


(Note 1)

CCA

Outdoor Air Damper

To UPC

CCHR

Red

Black

RV

HPLP

T

FP1RV

T

FP2


RCP

CS

See Note 3


Blue (22)

Blue (23)

BlueBlue

UltraTech

Brown (31)

Orange (1)

Orange (2)

Yellow (3)

Yellow (4)

Yellow (5)

Yellow (6)

Blue (7)

Blue (8)

Black (9)

Black (10)

ValveWater Valve

Red

RedBlack

Black

Red

Reheat Valve

HW

P8

MOTOR

P6

RS485

P7

ZONE

P9

ABC


NOCOM

K6

NOCOM

K5

C

R

L1

L1

L2

L2P10 P5 P11

CR(-)(+)

CR(-)(+)

CR(-)(+)

P4 P2

K1K2K3


P3

V+CRTXRX

+5

P14LLTP1

LATFLOWLWTEWT

CT24 3

CT24 3

CT12 1

CT12 1

StatusG

DISCHP16

P17 P18 P15


SW1

Modbus Add. ID

Future Use12345

ONOFF



SCT2 13

HW12

C

P12SCP

2 13

Heat Shrink

Red

GreenWhite

T

T

T

T


White

Gray

Brown

Gray

Brown

White

Violet Violet


32

1

Gray

Red

Black~

Y

COM

TBlue

Blue

GNDOUT

RedWhite

5DC321Black

Gray

Compressor A T2

Compressor A T1

Red

Red

Blue

Blue

Economizer Damper

12

34

~

COM

Y

U

12

34

~

COM

Y

U

Black

Red

Orange

Orange

Gray

Orang

e

Gray

GND

OUT

5DC

324Brow

n

FLOW METER

Green

White

Black

Red

Red

SU CTI ONPRES SU RE

TRA NSD UCER

DISCHARGEPRESSURE

TRANSDUCERGN

DOU

T5DC

123W

hiteBlack

Red

Wiring Schematics - J


57


Accessory Relay



Operation


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6











Flash Code 1OFF


Flash Code 8




CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF




Reheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

L1 L2 L3

L2L1 L3

Unit Power Supply

L1 L2 L3

L2L1 L3

G


Blow

er F

uses

F7 F8 F9

Compressor

CCAT1

L1

T2

L2

T3

L3

T1

T2

T3

Green / Yellow

Black (G)

White (H)Red (J)

Black/White (16)

Yellow (17)

24V

Tran

sfor

mer

Red (T) White (S) Black (R)


Control Box Door

PB1

2

1

3

Gree

n/Ye

llow

(15)

Class 2

Notes:

CCH

CCHR

L3L2L1



PGM

YY-OUT

C

Yellow (12)


Red (F)White (E)

Black (D)

Yellow (11)

Yellow

Black (13)

Black/White Black

Blac

k (K)

Whit

e (L)

Red (

M)

Black (N)

Black (P)

Black (Q)

White (B)

Black (A)

Red (C)

BlowerMotor

L1

L2

L3

Black

Black

IDB (D-)

A (D+ )

GN D

IDB (D-)

A (D+ )

GN D

GN Dfo ut


Black

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123






EX-X


Current Transducer


Wiring Schematics - J (cont.)

58


CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On



RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

P1/P9

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO

CC2G REVREV FP1 FP1 FP2 FP2 LPS LPSHPSHPS


K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

CCA

Violet (31) Black (32)

CFM

P13

P4

SW1

P5JW2

P9

LO

O/B

Y2WDH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On



RV – B/OFP2 – 15°F/30°FFP1 – 15°F/30°F

Com1LED5

Com2LED5

Test Mode

F1-3A

C

PWM

12345678


RC

GY1


Off

Faul tLED1

R

StatusLED3

ConfigLED2


CC2LO

CC2G REVREV FP1 FP1 FP2 FP2 LPS LPSHPSHPS

Aurora Base Control B(ABC-B)

K1-RV Relay

K2-CC Relay

K3-CC2 Relay


K6-Acc Relay

F

R

C

CCGY1C

R

ESLS

P2EH1

YG G

G

Condensate

Brown (37)

CCB

Violet/White (35)

Black/White (36)

Tan

(Note 1)

P1/P9(Note 1)

Red

CCHR

Valve

RHA

Tan

RHB

Tan/White

Tan/White

Outdoor Air Damper

Red

Black

To UPC

RV

HP-A

Black(10)

Black(9)

Blue(8)

Blue(7)

LP-A

T

Yellow(4)

Yellow(3)

FP1-A

Orange(2)

Orange(1)

RV-A

T

Black

Black

FP2-A

HP-B

Black/White(30)

Black/White(29)

Blue/White(28)

Blue/White(27)

LP-B

T

Yellow(24)

Yellow(23)

FP1-B

Orange/White(22)

Orange/White(21)

RV-B


Valve

Brown (38)

White

RV

To AXB-B

To AXB-A

To UPC

Condensate

Brown (37)

Brown (38)

T

Black

Black

FP2-B

See Note 2

See N

ote 2

See Note 2

See Note 2

Blac

k

Gray

Wiring Schematics - K

Rooftop 096-360 Dual Compressor Aurora Base, 208-230-460/60/3, Plenum Fan

59


Accessory Relay



Operation

CC2

EH1

Fact

ory

Faul t

ALG

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

noAC

C nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWM

Fact

ory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF




Reheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

12345678

Off On

N/A

RS48

5 NE

T

LED3

LED2LED1

L1 L2 L3

L2L1 L3

Unit Power Input

L1 L2 L3

L2L1 L3

GNon-Fused Di sconnect, or HACR Break er

Blow

er 1

Fus

es

F1 F2 F3

Compressor A

CCAT1

L1

T2

L2

T3

L3

T1

T2

T3

Compressor B

CCBT1

L1

T2

L2

T3

L3

T1

T2

T3

Green / Yellow (G1) Green / Yellow (G2)

BlowerMotor

Black (K)

White (L)

Red (M)

Black (K)White (L)

Red (M)

Black/White (18)

Black/White (20)

Yellow (17)

Yellow (19)

24V

Tran

sfor

mer

L3L2L1


(closest to control box)


Red (Q)White (P)

Black (N)Red (T)

White (S)

Black (R)

Yellow (13)

PGM

YY-OUT

C

Black/White

Yellow

Black (14)

Yellow (11)

Green / Yellow (39)Control Box Base Panel

Control Box Door

Black

PB1

2

1

3Green/Yellow (15)

Class 2

1 – P1 (screw terminals) and P9 (Molex connector) are adjacent and share common terminals in the same order.2 – Optional isolation and/or reheat valve. If valve(s) not present, wires are not connected and tied off.3 – Blower 2 on sizes 181-360 only.

Notes:

CCHB

CCHACCHR

Blower Motor 1

Green/Yellow (16)

L1 L2 L3

L2L1 L3

Blow

er 2

Fus

es

F4 F5 F6

L2L1 L3

L1 L2 L3

1

Black (X)

White (Y)

Red (Z)

Black (X)White (Y)

Red (Z)

Red (W)

White (V)Black (U) Red (J)

White (H)Black (G)

Termi na l Bl oc k

Blac

k (AA

)W

hite (

AB)

Red (

AC)

BlowerMotor

2

See Note 3

See N

ote 3

White (E)Red (F)

Black (A)White (B)

Red (C)

Black (D)

24V

Tran

sfor

mer

Red for 208VBlue for 230VRed for 460VClass 2

BlackYellow (12)

Yellow

Blower Motor 2

IDB (D-)

A (D+ )

GN D

IDB (D-)

A (D+ )

GN D

GN Dfo ut

IDB (D-)

A (D+ )

GN D

IDB (D-)

A (D+ )

GN D

GN Dfo ut

See Note 3

Black (AD)Black (AE)

Black

Black (AF) Black

Black

BlackBlack (AG)

Black (AH)

Black/White

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123

CCA – Compressor A ContactorCCB – Compressor B ContactorCO – Condensate Overflow SensorES – Emergency ShutdownHP1 – High Pressure Switch 1HP2 – High Pressure Switch 2LP1 – Low Pressure Switch 1LP2 – Low Pressure Switch 2FD1 – Freeze De tection Sensor 1FD2 – Freeze De tection Sensor 2F1 – Fuse




SW1 – Push buttonSW2 – DIP package 8 positionRB – Blower RelayRV1 – Reversing Valve Coi l 1RV2 – Reversing Valve Coi l 2PGM – Phase Guard Moni torRH – Reheat Valve Coi l

EX-X


Current Transducer

Rooftop 096-360 Dual Compressor Aurora Base, 208-230-460/60/3, Plenum Fan

Wiring Schematics - K (cont.)

60


Compressor A T2

SCT

SUC

PHW HW

BlueBlueRedRed

P8

MOT

OR P6

RS48

5 P7

ZONE P9

ABC

STEP

PER

ANA

ACC2

DHDI

V

NO

CO

M

K6

NO

CO

M

K5

C R L1 L1 L2 L2P1

2P1

0P5

P11

CR(-)(+) CR(-)(+) CR(-)(+)

P4P2

K1K2

K3

HA2

HA1

SGI

LOO

PVS

DAT

AVS

PUM

PPU

MPSL

AVE

P3

V+CRTXRX +5

P14

LLT

P1LA

TFL

OW

LWT

EWT

CT2

43

CT2

43

CT1

21

CT1

21

StatusG

DISC

HP1

6

P17

P18

P15

(Aurora Expansion Board A)

AXB™-A

SW1

Modbus Add. IDFuture Use

12345

ONOFF


See Figure 1 for DHW wiring.

SW1-4 SW1-5 DESCRIPTIONON ON Cycles with BlowerOFF ON Cycles with CC rst stage compressor or compressor spd 1-12ON OFF Cycles with CC2 second stage of compressor or comp spd 7-12OFF OFF Cycles with DH from ABC board

AXB Accessory 2 DIP Se ngs

CS

+5C

CC

21

INOU

T+5

S

To ABC-A

FLOW METER (096-144)

T

T

TBrown

Brown

1

3

2

4

White

Green

Brown

1

3

2

4Purple

Purple

White

White

T

Gray

GrayGray

Gray

Compressor A T1White

White

Purple

Purple

White

Gray

Green

Red

Heat Shrink

Red

Economizer Damper

Orange

1 2 3 4

~COM Y U

Black

Red

Gray


3 2 1

~Y COM

Gray

1 2 3 4

~COM Y U

BlackRed

Orange

Orange

GNDOUT

RedWhiteBlack SUCTION

PRESSURE TRANSDUCER5DC3

21

Black

RedWhite

Blue TBlue

GNDOUT5DC

123

DISCHARGEPRESSURE

TRANSDUCER

Gray

Gray

Black To PB1-2

To PB1-2To PB1-1

To PB1-1

Wiring Schematics - K+L

Rooftop 096-360 Aurora Advanced Controls, Dual Compressor

61


Compressor B T2

Compressor B T1

SCT

SUC

PHW HW

Blue/WhiteBlue/White

Red/WhiteRed/White

P8

MOT

OR P6

RS48

5 P7

ZONE P9

ABC

STEP

PER

ANA

ACC2

DHDI

V

NO

CO

M

K6

NO

CO

M

K5

C R L1 L1 L2 L2P1

2P1

0P5

P11

CR(-)(+) CR(-)(+) CR(-)(+)

P4P2

K1K2

K3

HA2

HA1

SGI

LOO

PVS

DAT

AVS

PUM

PPU

MPSL

AVE

P3

V+CRTXRX +5

P14

LLT

P1LA

TFL

OW

LWT

EWT

CT2

43

CT2

43

CT1

21

CT1

21

StatusG

DISC

HP1

6

P17

P18

P15

(Aurora Expansion Board B)

AXB™-B

SW1


12345

ONOFF



CS

+5C

CC

21

INOU

T+5

S

To ABC-B

TBro wn/WhiteBrown/White


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6











Flash Code 1OFF


Flash Code 8




GNDOUT

RedWhiteBlack

5DC321

Black

RedWhite

Blue TBlue

GNDOUT5DC

123

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123

CCA – Compressor A ContactorCCB – Compressor B ContactorCO – Condensate Overflow SensorES – Emergency ShutdownEWT – Entering Water Temp SensorHP1 – High Pressure Switch 1HP2 – High Pressure Switch 2LAT – Leaving Ai r TempLLT – Liquid Line TempLP1 – Low Pressure Switch 1LP2 – Low Pressure Switch 2LWT – Leaving Water Temp



Light Emitti ng Diode - RedREX

-XX Pin Number Designation on

Twist-Lock Connector

Current Transducer


DISCHARGEPRESSURE

TRANSDUCER

SUCTION PRESSURE

TRANSDUCER

Rooftop 096-360 Aurora Advanced Controls, Dual Compressor

Wiring Schematics - K+L (cont.)

62


Wiring Schematics - M

Rooftop 036-360 Single/Dual Compressor Aurora UPC

To ABC-A - P8

Yellow

Brown

Green

Blue

White

Black

Orange

Red

Devices Must Be Wired in Daisy Chain Configuration

GNDRNET+RNET-

+12V

OAT/OAH

1 2 3 4 5 6 7 8

RAT/RAH

BACnet or N2 Network

Connections

2W

4W

RNET LOCAL ACCESS

POWER

GND

24 VAC

FORM AT BATT

TEN’S

ONE’S

TXLED1

RXLED2

TXLED6

RXLED7

POWERLED3

RUNLED4

ERRLED5

0

5

23

87

1

4

9

6

0

5

23

87

1

4

9

6

LON ADAPTER

PORT

NET+

NET-

COM

NET+

NET-

N/C

N/C

Signal

GNDRNET+RNET-+12V

GNDLN+LN-+12

/S

ON

12

34

56

78

Optional LON Add-On Module

A

N/C

N/C

Signann l

Service

ECH

ELON

12

Net

LED1

LED2

LED3

LED4

Tx

Rx

LON OC

MAC Address Setting

Communication Options

NET

+

NET

-

CO

M

NET

+

NET

-

CO

M

12

1 2

LON Network Connections

Devices Must Be Wired in Daisy Chain Configuration

LegendFactory Low Voltage WiringField Low Voltage Wiring

12345678RJ45 Connector

Optional Block

NOTE 1

To ABC-B - P8

1 2 3 4 5 6 7 8

Yellow

Brown

Green

Blue

White

Black

Orange

Red

Dual Compressor Only

GNDRNET+RNET-

+12V

Economizer OperationEconomizer Mode: Sensors Used:Differential Enthalpy

Fixed Enthalpy

Differential Dry Bulb

Fixed Dry Bulb

19P662-01 (x2)

19P662-01

19P662-02 (x2)

19P662-02

Network Controlled None (See Note 2)

Notes 1. Use DIP Switches 5 – 8 to change communication protocol and DIP switches 1 – 2 to change BACnet baud rate

2. Network controlled economizer must be used with at least one differential enthalpy economizer.

63


Wiring Schematics - N

Rooftop 360 Compressor Protection Module


Less than 1 second




2 minutes

2 minutes













OFFON



Flash Code 6











Flash Code 1OFF


Flash Code 8




Compressor A

Green / Yellow (G2)

L2 L3L1T2T1

M2M1Compressor Protec on Module A

T3

T2

T1

ABC-A R F FG CC CCG

CC2HI

CC2

LO

CC2G

P5

P6

RS485 EXP

C R - +

R

C

F1-3A

RS485 NET

CR P8LO O

/B

Y2 W DH

R C G Y1 P

7

RS485 EXP

C R - +

CCA

CCHR

Black (34)

Violet (33)

Violet (31)

To CCA

Black (32)

Blue

Blue

64


Wiring Schematics - N (cont.)

Rooftop 360 Compressor Protection Module

Thermistor

Relay Coi l



Polarized connector



Field Wiring Lug

Ground



Legend

L1

Capacitor

T

123

CC1 – Compressor 1 ContactorCC2 – Compressor 2 ContactorCCH – Crankcase HeaterCO – Condensate Overflow SensorES – Emergency ShutdownHP1 – High Pressure Switch 1HP2 – High Pressure Switch 2LP1 – Low Pressure Switch 1LP2 – Low Pressure Switch 2FD1 – Freeze De tection Sensor 1FD2 – Freeze De tection Sensor 2F1 – Fuse




SW1 – Push buttonSW2 – DIP package 8 positionRB – Blower RelayRV1 – Reversing Valve Coi l 1RV2 – Reversing Valve Coi l 2PGM – Phase Guard Moni torRH – Reheat Valve Coi l

EX-X


ABC-B R F FG CC CCG

CC2HI

CC2

LO

CC2G

P5

P6

RS485 EXP

C R - +

R

C

F1-3A

RS485 NET

CR P8LO O

/B

Y2 W DHR C G Y1 P

7

RS485 EXP

C R - +

Compressor B

Green / Yellow (G2)

L2 L3L1T2T1

M2M1Compressor Protec on Module A

T3

T2

T1

To CCB

CCABlack (32)

Violet (31)

Blue

Blue

65


Aurora Controls

Aurora ControlsThe Aurora Control System is a complete commercial comfort system that can bring all aspects of the HVAC system into

one cohesive module network. The Aurora System is available in two configurations: Aurora Base Control and Aurora Ad-

vanced Control both with optional Aurora UPC for DDC applications.

Control General Description Application Display/Interface Protocol

Aurora Base Control

The ABC microprocessor provides all the features necessary to operate today’s standard WSHPs that utilize dual capacity compressors and variable speed ECM/5 speed ECM blower motors with hot gas reheat. This control can communicate to a handheld diagnostic tool to help the installing contractor or service technician with equipment setup and service. By utilizing Modbus RTU communication protocol, the ABC board can communicate with additional devices on the Aurora network

Used for residential and commercial applications that use single or dual capacity compressors with PSC, 5-speed ECM, or variable speed ECM blower motors. This base control can also communicate to the AID Tool to display faults, inputs/outputs, and software revision. Commercial features such as hot gas reheat, slow opening water valve, and random start are also capable with the ABC board.

Optional AID toll can be used for field service.

Standalone

Aurora Advanced Control (ABC/AXB)

Aurora Advanced Control adds the AuroraAXB expansion board and provides added I/O and standard features such as refrigerant, performance or energy monitoring.

• Refrigeration Monitoring – provides Suction and discharge pressure,Suction, liquid line temps and superheat and subcooling.

• Performance Monitoring – provides entering and leaving loop water temperatures, loop flow rate as well as heat of extraction or rejection rate into the loop.

• Energy Monitoring – provides real-time power measurement (Watt) of compressor, fan, auxiliary heat andzone pump.

• Plus many more I/O options

Optional AID tool can be used for field service.

Standalone

Aurora Base/Aurora Advanced

Control w/UPC BACnet or N2

The Aurora Unitary Protocol Converter (UPC) is an integrated solution and communicates directly with the Aurora Heat Pump Controls and allows access/control of a variety of internal Aurora heat pump operations such as sensors, relay operation, faults and other information. In turn, the UPC then converts internal Aurora Modbus protocol to BACnet MS/TP, or N2 protocols and communicates to the BAS system. This provides the great benefit of complete control integration and a myriad of information available to the BAS from the heat pump control. Plus it also allows individual unit configuration such as ECM fan speeds or freeze protection setting directly over the BAS without the need for access to the actual heat pump.

The Aurora UPC is implemented with the Aurora heat pump control into our latest water source heat pumps. All Internal Aurora points are accessible to the UPC via firmware providing an integrated solution. All zone temperatures and zone sensors are connected to the UPC on an RNet bus, simplifying hook up at the unit. RNet sensors can include a combination of zone temperature and humidity, CO2, and VOC sensors. The UPC includes built-in support for a custom configurable keypad/display unit.

Optional Aurora Touch

BACnet MS/TP or N2 Open (DIP selectable)

Aurora Base/Aurora Advanced

Control w/UPC LonWorks

The Aurora Unitary Protocol Converter (UPC) is an integrated solution and communicates directly with the Aurora Heat Pump Controls and allows access/control of a variety of internal Aurora heat pump operations such as sensors, relay operation, faults and other information. In turn, the UPC then converts internal Aurora Modbus protocol to LONWorks protocol and communicates to the BAS system.

The Aurora UPC is implemented with the heat pump control into our latest water source heat pumps. All Internal Aurora points are accessible to the UPC via firmware providing an integrated solution. All zone temperatures and zone sensors are connected to the UPC on an RNet bus, simplifying hook up at the unit. RNet sensors can include a combination of zone temperature and humidity, CO2, and VOC sensors. The UPC includes built-in support for a custom configurable keypad/display unit.

Optional Aurora Touch

LonWorks

66


Controls - Aurora Base Control

Aurora ‘Base’ Control

NOTE: Refer to the Aurora Base Control Application and

Troubleshooting Guide and the Instruction Guide: Aurora

Interface and Diagnostics (AID) Tool for additional information.

The Aurora Base Control provides all baseline operation

of 7 faults (HP, LP and LOC, coax freeze protection, air coil

Freeze protection, over/under Voltage and condensate

overflow), as well as compressor and fan speed and lockout

management through the single ABC board (Aurora Base

Control). The control features all heat pump operational

timings, configurations, sensors and fault history that can

be viewed using then AID tool.

Optional Aurora UPC

When coupled with the optional Aurora UPC, the system

can communicate all of these same heat pump parameters

to the BAS as network points using either BACnet, N2 or

Lon protocols. This means that not only are heat pump

parameters visible by the BAS, many configuration settings,

such as airflow and freeze detection settings, can also

be changed from the BAS system saving commissioning

costs. This provides both cost advantages and features

not typically found on WSHP controls. All configuration,

sensor and servicing can be accessed thru the AuroraTouch

color service tool. This integration allows heat pump

monitoring sensors, status and service diagnosis faults

to be communicated thru the DDC direct to the building

automation system (BAS), giving building supervisors

detailed and accurate information on every piece of

equipment without removing an access panel!

Control FeaturesSoftware ABC Standard Version 3.0

Single or Dual Capacity CompressorsEither single or dual capacity compressors can be operated.

Variable Speed ECM

Blower Motor Option (If Applicable)A Variable Speed ECM blower motor can be driven directly

using the onboard PWM output. Four blower speeds are

available based upon the G, Y1, Y2, and W input signals to

the board. The blower speeds can be changed either by the

ECM manual configurations mode method or by using the

Aurora AID Tool directly. All four blower speeds can be set

to the same speed if desired.

5-Speed ECM Blower Motor Option (If Applicable)

A 5-Speed ECM blower motor will be driven directly using

the thermostat connections. Any of the G, Y1, or Y2/W

signals can drive any of the 5 available pre-programmed

blower speeds on the motor.

Other Control Features• Random start at power up

• Anti-short cycle protection

• High and low pressure cutouts

• Loss of charge

• Water coil freeze detection

• Air coil freeze detection

• Over/under voltage protection

• Condensate overflow sensor

• Load shed

• Dehumidification (where applicable)

• Emergency shutdown

• Hot gas reheat operation (where applicable)

• Diagnostic LED

• Test mode push button switch

• Two auxiliary electric heat outputs

• Alarm output

• Accessory output with N.O. and N.C.

• Modbus communication (master)

• Modbus communication (slave)

67


Controls - Aurora Base Control cont.DIP Switch (SW2)

SW2-1 FP1 Selection – Low water coil temperature limit

setting for freeze detection. On = 30°F; Off = 15°F.

SW2-2 FP2 Selection – On = 30°F; Off = N/A

SW2-3 RV – O/B - thermostat type. Heat pump

thermostats with “O” output in cooling or “B”

output in Heating can be selected. On = O; Off = B.

SW2-4 Access Relay Operation (P2)

and 2-5

Access Relay Operation SW2-4 SW2-5

Cycle with Blower ON ON

Cycle with Compressor OFF OFF

Water Valve Slow Opening ON OFF

Cycle with Comm. T-stat Hum Cmd OFF ON

Cycle with Blower - The accessory relay will cycle with the

blower output.

Cycle with Compressor - The accessory relay will cycle

with the compressor output.

Water Valve Slow Opening - The accessory relay will

cycle and delay both the blower and compressor output

for 90 seconds.

SW2-6 CC Operation – selection of single or dual capacity

compressor. On = Single Stage; Off = Dual Capacity

SW2-7 Lockout and Alarm Outputs (P2) – selection of a

continuous or pulsed output for both the LO and

ALM Outputs. On = Continuous; Off = Pulsed

SW2-8 Future Use

Alarm Jumper Clip Selection

From the factory, ALM is connected to 24 VAC via JW2. By

cutting JW2, ALM becomes a dry contact connected to ALG.

Variable Speed ECM Blower Speeds

The blower speeds can be changed either by using the

ECM manual configurations mode method or by using the

Aurora AID Tool directly (see Instruction Guide: Aurora

Interface and Diagnostics (AID) Tool topic).

Field Selectable Options via HardwareDIP Switch (SW1) – Test/Configuration Button (See SW1 Operation Table)

Test Mode

The control is placed in the test mode by holding the push

button switch SW1 for 2 - 5 seconds. In test mode most of

the control timings will be shortened by a factor of sixteen

(16). LED3 (green) will flash at 1 second on and 1 second

off. Additionally, when entering test mode LED1 (red) will

flash the last lockout one time. Test mode will automatically

time out after 30 minutes. Test mode can be exited by

pressing and holding the SW1 button for 2 to 5 seconds or

by cycling the power. NOTE: Test mode will automatically

be exited after 30 minutes.

Variable Speed ECM Configuration Mode

(If Applicable)

The control is placed in the ECM configuration mode by

holding the pushbutton switch SW1 for 5 to 10 seconds, the

high, low, and “G” ECM speeds can be selected by following

the LED display lights. LED2 (yellow) will fast flash when

entering the ECM configuration. When setting “G” speed

LED3 (green) will be continuously lit, for low speed LED1

(red) will be continuously lit, and for high speed both LED3

(green) and LED1 (red) will be continuously lit. During the

ECM configuration mode LED2 (yellow) will flash each of

the 12 possible blower speeds 3 times. When the desired

speed is flashed press SW1, LED2 will fast flash until SW1

is released. “G” speed has now been selected. Next select

low speed, and high speed blower selections following the

same process above. After third selection has been made,

the control will exit the ECM configuration mode. Aux fan

speed will remain at default or current setting and requires

the AID Tool for adjustment.

Reset Configuration Mode

The control is placed in reset configuration mode by

holding the push button switch SW1 for 50 to 60 seconds.

This will reset all configuration settings and the EEPROM

back to the factory default settings. LED3 (green) will turn

off when entering reset configuration mode. Once LED3

(green) turns off, release SW1 and the control will reset.

68


Controls - Aurora Base Control cont.removed, all of the emergency heat outputs will turn off, and

the ECM blower will shift to “G” speed and PSC blower motor

output will remain on.

High Pressure – fault is recognized when the Normally

Closed High Pressure Switch, P4-9/10 opens, no matter

how momentarily. The High Pressure Switch is electrically in

series with the Compressor Contactor and serves as a hard-

wired limit switch if an overpressure condition should occur.

Low Pressure - fault is recognized when the Normally

Closed Low Pressure Switch, P4-7/8 is continuously open

for 30 seconds. Closure of the LPS any time during the 30

second recognition time restarts the 30 second continuous

open requirement. A continuously open LPS shall not be

recognized during the 2 minute startup bypass time.

Loss of Charge – fault is recognized when the Normally

Closed Low Pressure Switch, P4-7/8 is open prior to the

compressor starting.

Condensate Overflow - fault is recognized when the

impedance between this line and 24 VAC common or chassis

ground drops below 100K ohms for 30 seconds continuously.

Freeze Detection (Coax) - set points shall be either 30°F

or 15°F. When the thermistor temperature drops below

the selected set point, the control shall begin counting

down the 30 seconds delay. If the thermistor value rises

above the selected set point, then the count should reset.

The resistance value must remain below the selected set

point for the entire length of the appropriate delay to be

recognized as a fault. This fault will be ignored for the initial

2 minutes of the compressor run time.

Freeze Detection (Air Coil) - uses the FP2 input to protect

against ice formation on the air coil. The FP2 input will

operate exactly like FP1 except that the set point is 30

degrees and is not field adjustable.

Over/Under Voltage Shutdown - An over/under voltage

condition exists when the control voltage is outside the

range of 18 VAC to 30 VAC. If the over/under voltage

shutdown lasts for 15 minutes, the lockout and alarm relay

will be energized. Over/under voltage shutdown is self-

resetting in that if the voltage comes back within range

of 18 VAC to 30 VAC for at least 0.5 seconds, then normal

operation is restored.

Field Selectable Options via Software(Selectable via the Aurora AID Tool)

ECM Blower Speeds

An ECM blower motor can be driven directly using the

onboard PWM output. Four blower speeds are available,

based upon the “G”, Y1 (low), Y2 (high), and Aux input

signals to the board. The blower speeds can be changed

either by the ECM manual configurations mode method (see

ECM Configuration Mode topic) or by using the Aurora AID

Tool directly. All four blower speeds can be set to the same

speed if desired. Aux blower speed will remain at default or

current setting and requires the AID Tool for adjustment.

Safety FeaturesThe following safety features are provided to protect the

compressor, heat exchangers, wiring and other components

from damage caused by operation outside of design conditions.

Fuse – a 3 amp automotive type plug-in fuse provides

protection against short circuit or overload conditions.

Anti-Short Cycle Protection – 4 minute anti-short cycle

protection for the compressor.

Random Start – 5 to 80 second random start upon power up.

Fault Retry – in the fault condition, the control will stage off

the outputs and then “try again” to satisfy the thermostat

Y input call. Once the thermostat input calls are satisfied,

the control will continue on as if no fault occurred. If 3

consecutive faults occur without satisfying the thermostat

Y input call, then the control will go to Lockout mode.

Lockout – when locked out, the blower will operate

continuously in “G” speed, and PSC blower motor output

will remain on. The Alarm output (ALM) and Lockout output

(L) will be turned on. The fault type identification display

LED1 (Red) shall flash the fault code. To reset lockout

conditions with SW2-8 On, thermostat inputs “Y1”, “Y2”,

and “W” must be removed for at least 3 seconds. To reset

lockout conditions with SW2-8 Off, thermostat inputs “Y1”,

“Y2”, “W”, and “DH” must be removed for at least 3 seconds.

Lockout may also be reset by turning power off for at least

30 seconds or by enabling the emergency shutdown input

for at least 3 seconds.

Lockout With Emergency Heat - if the control is locked out

in the heating mode, and a Y2 or W input is received, the

control will operate in the emergency heat mode while the

compressor is locked out. The first emergency heat output will

be energized 10 seconds after the W input is received, and the

blower will shift to high speed. If the control remains locked

out, and the W input is present, additional stage of emergency

heat will stage on after 2 minutes. When the W input is

69


Controls - Aurora Base Control cont.Single Compressor Cooling, 2nd Stage (Y1, Y2, 0) The compressor will be staged to full capacity 20 seconds

after Y2 input was received. The ECM blower will shift to high

speed 15 seconds after the Y2 input was received.

Dual Compressor Cooling, 2nd Stage (Y1, Y2, O) In dual compressor operation, two ABC boards used in 24

VAC operation, there will be a Y2 call to the Y1 input on the

second ABC. The compressor will stage to full capacity 30

seconds after Y1 input is received to the second board.

Blower (G) - The blower will start immediately upon

receiving a thermostat G command. If there are no other

commands from the thermostat the ECM will run on “G”

speed until the G command is removed. Regardless of

blower input (G) from the thermostat, the blower will

remain on for 30 seconds at the end of each heating,

cooling, and emergency heat cycle.

Dehumidification (Y1, O, DH or Y1, Y2, O, DH) - When a

DH command is received from the thermostat during a

compressor call for cooling the ECM blower speed will be

reduced by 15% to increase dehumidification.

Emergency Shutdown - Four (4) seconds after a valid ES

input, P2-7 is present, all control outputs will be turned off

and remain off until the emergency shutdown input is no

longer present. The first time that the compressor is started

after the control exits the emergency shutdown mode,

there will be an anti-short cycle delay followed by a random

start delay. Input must be tied to common to activate.

Continuous Blower Operation - The blower output will

be energized any time the control has a G input present,

unless the control has an emergency shutdown input

present. The blower output will be turned off when G input

is removed.

Load Shed - The LS input disables all outputs with the

exception of the blower output. When the LS input has been

cleared, the anti-short cycle timer and random start timer

will be initiated. Input must be tied to common to activate.

Operation DescriptionPower Up - The unit will not operate until all the inputs and

safety controls are checked for normal conditions. The unit

has a 5 to 80 second random start delay at power up. Then

the compressor has a 4 minute anti-short cycle delay after

the random start delay.

Standby In standby mode, Y1, Y2, W, DH, and G are not

active. Input O may be active. The blower and compressor

will be off.

Heating Operation

Single Compressor Heating, 2nd Stage (Y1, Y2) The compressor will be staged to full capacity 20 seconds

after Y2 input is received. The ECM blower will shift to high

speed seconds after the Y2 input is received.

Dual Compressor Heating, 2nd Stage (Y1, Y2) In dual compressor operation, two ABC boards used in 24

VAC operation, there will be a Y2 call to the Y1 input on the

second ABC. The compressor will stage to full capacity 30

seconds after Y1 input is received to the second board.

Single Compressor Heating, 3rd Stage (Y1, Y2, W) The hot water pump is de-energized and the first stage of

electric heat is energized 10 seconds after the W command

is received. If the demand continues the second stage of

electric heat will be energized after 5 minutes.

Dual Compressor Heating, 3rd Stage (Y1, Y2, W) - The first stage of electric heat is energized 10 seconds

after the W command is received. If the demand continues

the second stage of electric heat will be energized after 5

minutes

Emergency Heat (W) - The blower will be started on “G”

speed, 10 seconds later the first stage of electric heat will

be turned on. 5 seconds after the first stage of electric

heat is energized the blower will shift to Aux speed. If the

emergency heat demand is not satisfied after 2 minutes the

second electric heat stage will be energized.

Blower (G) - The blower will start immediately upon

receiving a thermostat G command. If there are no other

commands from the thermostat the ECM will run on “G”

speed until the G command is removed. Regardless of

blower input (G) from the thermostat, the blower will

remain on for 30 seconds at the end of each heating cycle.

Cooling Operation

In all cooling operations, the reversing valve directly tracks

the O input. Thus, anytime the O input is present, the

reversing valve will be energized.

70


CC2

EH1Fa

ctory

Faul tAL

G

ALMLSES ACC

c

Status


RV – K1

CC2

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ACC

no

ACC

nc


3A-Fu

se


LOG

HICCGCCFGFR

HPHPLP

FP2FP2FP1

REVREV

CFM

PWM

ECM PWMFa

ctory


R R

CC

C

RS 48

5

EH2C

EH1C

CO

(+)(-)RCRS

485 E

xpFa

ctory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 - Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13P4 FP2 – 15oF/30oF



L – Pulse/ContinuousReheat/Normal

Fact

ory U

se


C

LP

FP1

F

CC

G

Y1

1

2

3

4

5

6

7

8

Off On

N/A

RS48

5 NET

LED3

LED2LED1

Aurora ‘Base’ Control LED DisplaysThese three LEDs display the status, configuration, and fault codes for the control. These can also be read in plain English via the Aurora AID Tool.

Status LED (LED3, Green)

Description of Operation Fault LED, Green

Normal Mode ON

Control is Non-functional OFF

Test Mode Slow Flash

Lockout Active Fast Flash

Dehumidification Mode Flash Code 2

(Future Use) Flash Code 3


Load Shed Flash Code 5

ESD Flash Code 6


Configuration LED (LED2, Yellow)

Description of Operation Configuration LED, Yellow

No Software Overwritten Flashing ECM Setting

DIP Switch was Overwritten Slow Flash

ECM Configuration Mode Fast Flash

Fault LED (LED1, Red)

Red Fault LEDLED Flash

Code*Lockout

Reset/Remove

AB

C B

asi

c F

au

lts

Normal - No Faults OFF –

Fault - Input 1 No Auto

Fault - High Pressure 2 Yes Hard or Soft

Fault - Low Pressure 3 Yes Hard or Soft

Fault - Freeze Detection FP2 4 Yes Hard or Soft


Fault - Condensate Overflow 7 Yes Hard or Soft

Fault - Over/Under Voltage 8 No Auto

Fault - FP1 & FP2 Sensor Error 11 Yes Hard or Soft

NOTE: All codes >11 use long flash for tens digit and short flash for the ones digit. 20, 30, 40, 50, etc. are skipped.

Aurora Interface and Diagnostics (AID) ToolThe Aurora Interface and Diagnostics (AID) Tool is a device that is a member of the Aurora network. The AID Tool is used to troubleshoot equipment which uses the Aurora control via Modbus RTU communication. The AID Tool provides diagnostics, fault management, ECM setup, and system configuration capabilities to the Aurora family of controls. An AID Tool is recommended, although not required, for ECM airflow settings. The AID Tool simply plugs into the ABC-A board.

ABC Control Board Layout

Controls - Aurora Base Control cont.

71


Aurora Advanced Controls

The Aurora Advanced Control provides all of the Aurora

Base Control features plus it adds the extended I/O of the

Aurora Expansion Board (AXB) to the mix. This extended

I/O includes the energy monitoring as a standard feature

where current transducers measure current and power of

fan and compressor. An optional refrigeration monitoring

kit is available to report refrigerant temperatures and pres-

sures and will calculate superheat and subcooling. The op-

tional performance kit includes entering and leaving water

temperatures along with source water flow rate via a vortex

shedding flow meter and will calculate heat of extraction/

rejection ratio on the waterside.

Optional Aurora UPC

When coupled with the optional Aurora UPC, can com-

municate all of these same heat pump parameters to the

BAS as network points using either BACnet MS/TP, N2 or

Lon protocols. This means that not only are heat pump

parameters visible by the BAS, many configuration settings,

such as airflow and freeze detection settings, can also be

changed from the BAS system saving commissioning costs.

All configuration, sensor and servicing can be accessed

through the AuroraTouch color service tool. With the op-

tional Advanced controls and the monitoring kits installed

refrigeration, performance and energy consumption are all

cost effectively transmitted to the BAS!

Aurora ‘Advanced’ Control FeaturesThe Aurora ‘Advanced’

Control system expands on

the capability of the Aurora

‘Base’ Control (ABC)

by adding the Aurora

Expansion Board (AXB).

All of the preceding

features of the Aurora

‘Base’ Control are included.

The following control

description is of the

additional features and

capability of the Aurora

advanced control.

It is highly recommended the

installing/servicing contractor obtain

an Aurora Interface and Diagnostic

Tool (AID) and specialized training

before attempting to install or service

an Aurora ‘Advanced’ control system.

The additional AXB features include the following:

Leaving Air Temperature Sensor

Standard on all Aurora Advanced Controls is a leaving

air (discharge air) sensor. This sensor is pre-mounted for

downflow applications and will need to be repositioned for

side discharge applications in a high velocity location for

best results

AXB DIP Switch

DIP 1 - ID: This is the AXB ModBus ID and should always

read On.

DIP 2 & 3 - Future UseDIP 4 & 5 - Accessory Relay2: A second, DIP configurable,

accessory relay is provided that can be cycled with the

compressor 1 or 2 , blower, or the Dehumidifier (DH)

input. This is to complement the Accessory 1 Relay on

the ABC board.

Position DIP 4 DIP 5 Description

1 ON ON Cycles with Fan or ECM (or G)

2 OFF ONCycles with CC1 first stage of compressor

or compressor spd 1-6

3 ON OFFCycles with CC2 second stage of

compressor or compressor spd 7-12

4 OFF OFF Cycles with DH input from ABC board

Compressor Monitoring

The AXB includes two current transducers to monitor the

compressor current and starting characteristics. Open

circuits or welded contactor faults will be detected. This

fault will produce an E10 code.

Controls - Aurora 'Advanced' Control

72


Variable Speed Pump

This input and output are provided to drive and monitor

a variable speed pump. The VS pump output is a PWM

signal to drive the variable speed pump. The minimum and

maximum level are set using the AID Tool. 75% and 100%

are the default settings respectively. The VS data input

allows a separate PWM signal to return from the pump

giving fault and performance information. Fault received

from the variable speed pump will be displayed as E16.

Consult factory for application assistance.

Modulating Water Valve

This output is provided to drive a modulating water valve.

Through advanced design the 0-10VDC valve can be

driven directly from the VS pump output. The minimum

and maximum level are set in the same way as the VS

pump using the AID Tool. 75% and 100% are the default

settings respectively.

Advanced Communication Ports

Communication ports P6 and P8 will provide future

expansion via dedicated protocols. These are for future use.

Monitoring Sensor KitsEnergy Monitoring (Standard Sensor Kit on ‘Advanced’ models)

The Energy Monitoring Kit includes two current transducers

(blower and electric heat) added to the existing two

compressor sensors so that the complete power usage of

the heat pump can be measured. The AID Tool provides

configuration detail for the type of blower motor, power

adjustment and a line voltage calibration procedure to

improve the accuracy, and a power adjustment setting

that allows the compressor power to be adjusted to match

the unit's line voltage using the provided tables. This

information can be displayed on the AID Tool or selected

communicating thermostats. The TPCM32U03A/04A

will display instantaneous energy use while the color

touchscreen TPCC32U01 will in addition display a 13

month history in graph form. Refer to Unit Start Up Energy

Monitoring for configuration details.

Refrigerant Monitoring (optional sensor kit)

The optional Refrigerant Monitoring Kit includes two

pressure transducers, and three temperature sensors,

heating liquid line, suction temperature and existing cooling

liquid line (FP1). These sensors allow the measurement

of discharge and suction pressures, suction and liquid line

temperatures as well as superheat and subcooling. This

information will only be displayed on the AID Tool.

Performance Monitoring (optional sensor kit)The optional Performance Monitoring Kit includes three

temperature sensors, entering and leaving water, leaving

air temperature and a water flow rate sensor. With this kit

heat of extraction and rejection will be calculated. This

requires configuration using the AID Tool for selection of

water or antifreeze.

Special Modes and Applications5-Speed ECM Blower Motor (036-072)

Normally the 5-Speed ECM motor can be driven off

of thermostat signals and the ABC connector P9.

Communicating thermostats, however present a special

problem in this application since they operate without 24

VAC thermostat signals. The ABC board is wired to operate

these systems from the alternate relay output signals CC1,

CC2, Fan, and EH1 and should be wired for this.

Communicating Digital Thermostats

The Aurora controls system also features either mono-

chromatic or color touch screen graphic display

thermostats for user interface. These displays not only

feature easy to use graphical interface but display alerts

and faults in plain English. Many of the features discussed

here may not be applicable without these thermostats.

Dehumidification – Passive

In passive dehumidification mode, the airflow is reduced

by 15% from the heating airflow setting. If cooling airflow is

set to +5, -5 or -10% of heating airflow it will automatically

be set to -15% of heating airflow whenever the

dehumidification call is present in the communicating stat or from the thermostat input DH. If the airflow for cooling is already set to -15% no airflow change will be noticed from normal cooling. Dehumidification mode will be shown on the ABC and the communicating thermostats.

SCT

SUC

PHW HW

MOTO

R

RS48

5P7

ZONE

P9

ABC

STEP

PER

ANA

SPR

DHDI

V

NO

CO

M

K6

NO

CO

M

K5

C R L1 L1 L2 L2P1

2P1

0P5

P11

CR(-)(+) CR(-)(+) CR(-)(+)

P4P2

K1K2

K3

HA2

HA1

SGI

LOOP

PWM

VSSL

OSL

IP3

V+CRTXRX +5

P14

LLT

P1LA

TFL

OWLW

TEW

T

CT2

43

CT2

43

CT1

21

CT1

21

StatusG

DISC

HP1

6

P17

P18

P15



SW1


12345

ONOFF


P8 P6

AXB Control Board Layout

Controls - Aurora 'Advanced' Control cont.

73




Code *Lockout Reset/ Remove Fault Condition Summary

AB

C B

asi

c F

au

lts

Normal - No Faults Off -Fault-Input 1 No Auto Tstat input error. Autoreset upon condition removal.Fault-High Pressure 2 Yes Hard or Soft HP switch has tripped (>600 psi)Fault-Low Pressure 3 Yes Hard or Soft Low Pressure Switch has tripped (<40 psi for 30 continuous sec.)Fault-Freeze Detection FP2 4 Yes Hard or Soft Freeze protection sensor has tripped (<15 or 30 degF for 30 continuous sec.)Fault-Freeze Detection FP1 5 Yes Hard or Soft Freeze protection sensor has tripped (<15 or 30 degF for 30 continuous sec.)Fault-Condensate Overflow 7 Yes Hard or Soft Condensate switch has shown continuity for 30 continuous sec.Fault-Over/Under Voltage 8 No Auto Instantaneous voltage is out of range. **Controls shut down until resolved.Fault-FP1 Sensor Error 11 Yes Hard or Soft FP1 Sensor Open or Shorted

AB

C &

AX

B A

dvan

ce

d

Fau

lts

Fault-Compressor Monitor 10 Yes Hard or Soft Open Crkt, Run, Start or welded contNon-CriticAXB SnsrErr 13 No Auto Any Other Sensor Error

CriticAXBSnsrErr 14 Yes Hard or Soft Sensor Error for EEV or HW

Alert-HotWtr 15 No Auto HW over limit or logic lockout. HW pump deactivated.Fault-VarSpdPump 16 No Auto Alert is read from PWM feedback.Non-CritComErr 18 No Auto Any non-critical com errorFault-CritComErr 19 No Auto Any critical com error. Auto reset upon condition removalAlarm - Low Loop Pressure 21 No Auto Loop pressure is below 3 psi for more than 3 minutesAlarm - Home Automation 1 23 No Auto Closed contact input is present on Dig 2 input - Text is configurableAlarm - Home Automation 2 24 No Auto Closed contact input is present on Dig 3 input - Text is configurable

NOTES: *All codes >11 use long flash for tens digit and short flash for the ones digit. 20, 30, 40, 50 etc. are skipped!Alert’ is a noncritical sensor or function that has failed. Normal operation of the heat pump is maintained but service is desired at some point.

Aurora ‘Advanced’ Control LED DisplaysThese three LEDs display the status, configuration, and fault codes for the control. These can also be read in plain English via the Aurora AID Tool.

Status LED (LED3, Green)Description of Operation Fault LED, Green

Normal Mode ON






Emergency Shutdown Flash Code 6

On Peak Mode Flash Code 7


(Future Use) Flach Code 9

Configuration LED (LED2, Yellow)Description of Operation Configuration LED, Yellow

No Software Overwritten ECM Setting

DIP Switch Overwritten Slow Flash


Reset Configuration Mode OFF

Operation Logic Data Table

Operation Logic TableHeating Cooling

STG1 STG2 STG3 EMERG Fan Only STG1 STG2 Reheat Fan OnlyCompressor On On On Off Off On On On Off

Reversing Valve Off Off Off Off Off On On On OnAux Heat Off Off Staged Staged Off Off Off Off OffAcc Relay On On On Off Off On On On Off

Fan Relay (PSC) On On On On On On On On OnLoop Pump On On On Off Off On On On OffHot Water On On Off Off Off On On NA Off

5-Speed ECM Speed Med Low Med High High High Low Med Low Med High High LowECM Speed Med High Aux Aux Low Med High High Low

T-Stat Signal Y1 Y1,Y2 Y1,Y2,W W G Y1,O Y1,Y2,O DH G

5/11/12

Controls - Aurora 'Advanced' Control cont.

74


The Aurora Unitary Protocol Converter (UPC) is designed to add-on to any Aurora based heat pump control. The Aurora Unitary Protocol Convertor (UPC) is designed to allow water source heat pumps to be integrated into Building Automation Systems (BAS) with ease. The Aurora UPC is an integrated solution and communicates directly with the Aurora Heat Pump Controls and allows access/control of a variety of internal Aurora heat pump operations such as sensors, relay operation, faults and other information. In turn, the UPC then converts internal Aurora Modbus protocol to BACnet MS/TP, LON, or N2 protocols and communicates to the BAS system. This provides the great benefit of complete control integration and a myriad of information available to the BAS from the heat pump control. Plus it also allows individual unit configuration such as ECM fan speeds or freeze protection setting directly over the BAS without the need for access to the actual heat pump. The Aurora UPC is programmed using the powerful Eikon object oriented.

The Aurora UPC is implemented with the Aurora Base Controller (ABC) heat pump control into our latest water source heat pumps. This will allow for a BAS to integrate

and communicate to the heat pump thru a choice of 3 different communication protocols. The Aurora UPC has the ability to communicate BACnet MS/TP, N2 open, or LonWorks (requires LON Plugin card). This flexibility is possible due to the onboard dipswitches which allow for the desired protocol and baud rate to be selected in the field. All zone temperatures and zone sensors are connected to the UPC on an RNet bus, simplifying hook up at the unit. RNet sensors can include a combination of zone temperature and humidity, CO2, and VOC sensors. The UPC includes built-in support for a custom configurable keypad/display unit - BACview6 (4-line by 40 character per line display) or BACview5 (2-line by 16 character per line display). Up to 2 Keypad/display units can be mounted remotely for configuration and troubleshooting.

There are an extensive number of points that the UPC has available over the network for integration into the BAS. Control programmers need to carefully determine which points they want to add into the BAS database. A list of the BACnet points, N2 points, and LON SNVTs are available along with their individual point descriptions by contacting the Commercial Solutions Group at 1-877-677-4420.

Aurora UPC Controller ZS Series Sensors

Controls - Aurora UPC DDC Control (optional)

75


Aurora UPC Features• Rugged enclosure made of GE C2950 Cycoloy plastic

• Built-in surge transient protection circuitry

• Operating range of -20° to 140°F; 10 to 95% relative hu-

midity, non-condensing

• Onboard CR123A battery has a life of 10 years with 720

hours of cumulative power outage

• Multi-Protocol field selectable communication port

that supports:

• EIA-485 BACnet MS/TP @ 9600, 19.2k, 38.4k, 76.8k baud

• Metasys N2 Open

• LonWorks TP/FT-10 (Requires optional LON plug-in

communication card)

• Status of all unit operating conditions and fault lockouts

• Visual LED’s for status of power, network communication,

processor operation, and errors

• Provides gateway into Aurora heat pump controls for

unsurpassed control flexibility

• Network point for commanding unit into load shed

• Network point for commanding unit into

emergency shutdown

• Network points to assist in fan speed selection

• Network points for freeze protection settings

• Heating and cooling control from a remotely located

zone sensor

• Rnet communication port which allows for multiple Rnet

zone sensors (5) to be connected for space temperature

averaging if desired.

• Local laptop or BACview connection for field service

• FCC, UL and CE listed. BTL Certification is pending

N2

BACnet

LonWorks

BAS

Rnet

Modbus

Aurora UPC Optional Features• BACview handheld display, needed for field configuration

of fan speeds, set points, etc.

• AID Tool for Aurora ABC configuration

and troubleshooting.

• Aurora Advanced Control adds the Aurora AXB

expansion board and provides added I/O and

standard features

• Optional Sensor Kits (requires Aurora Advanced

Control with AXB - Future Availability on Select

Models/Configurations)

• Refrigeration Monitoring – provides Suction and

discharge pressure, Suction, liquid line temps and

superheat and subcooling.

• Performance Monitoring – provides entering and

leaving loop water temperatures, loop flow rate as well

as heat of extraction or rejection rate into the loop.

• Energy Monitoring – provides real-time power

measurement (Watt) of compressor, fan, auxiliary heat

and zone pump.

• Graphics packages available in the future

Controls - Aurora UPC DDC Control (optional) cont.

76


Port 1a is used to

communicate to the

Building Automation

System (BAS). This

port’s settings are

configured through

the onboard dip

switches.

Port 2 is used to com-

municate to the Au-

rora Base Controller

(ABC).

Port 1b is used for the

LonWorks plugin.

Rnet port is used

for communicating

zone sensors.

BACview or local

laptop connection.

24Vac

Dip switches for

configuring the

communication

port protocol

and baud rate

for the BAS port.

Mac address

is set by 2

rotary dials.

Aurora Touch InterfaceUtilizing a touch-screen interface, the UPC provides a

technician the ability to configure and diagnose equipment

at the unit or from any room sensor for added accessibility

and simpler troubleshooting. The technician will have

full access to equipment status, parameter values,

temperature, and humidity sensing as well as access to

alarm and trend history. With website-like navigation,

the Aurora Touch Interface is easy to use and provides

important insight into the system so your building can

operate as efficiently as possible.


77


1. Leaving Air Temperature (LAT) Sensor – This 10 kOhm

NTC sensor is factory installed on all UPC equipped

heat pumps. It typically is attached to wiring inside

the blower cabinet on the suction side of the blower.

This sensor is attached on ABC FP2 pins available as

LAT AU-30.

1. Compressor Proving Sensors – This optional factory

installed current sensor is connected to confirm

compressor operation via the power wires. The sensor

is attached at ABC Y1 and available at point BV-65.

1. Valve End Switch – This optional input is setup for a field

installed flow valve end switch. This end switch input is

attached at ABC Y2 and available at point BV-67.

1. Fan Proving Sensors – This optional factory installed

current sensor is connected to confirm fan operation

via the power wires. The sensor is attached at ABC G

and available at point BV-33.

1. Occupancy Sensor - This standard feature includes a

field installed and wired room sensor with occupancy

sensor typically found in DDC systems. The RNet

room sensors can be found thru your commercial

representative. The occupancy Sensors are attached at

ABC 0 and can be found at point BV-49.

1. Dirty Filter Switch – This optional field installed switch

is connected to confirm dirty filter operation. The

dirty filter switch can be found thru your commercial

representative. The sensor is attached at ABC W and

available at point BV-63.

2. Fault, Configuration, and Status Codes – The codes

can be visible to the BAS if desired



Code *Lockout

Reset/ Remove

Fault Condition Summary

AB

C B

asi

c F

au

lts

Normal - No Faults Off -

Fault-Input 1 No Auto Tstat input error. Autoreset upon condition removal.

Fault-High Pressure 2 Yes Hard or Soft HP switch has tripped (>600 psi)

Fault-Low Pressure 3 Yes Hard or Soft Low Pressure Switch has tripped (<40 psi for 30 continuous sec.)

Fault-Freeze Detection FP2 4 Yes Hard or Soft Freeze protection sensor has tripped (<15 or 30 degF for 30 continuous sec.)

Fault-Freeze Detection FP1 5 Yes Hard or Soft Freeze protection sensor has tripped (<15 or 30 degF for 30 continuous sec.)

Fault-Condensate Overflow 7 Yes Hard or Soft Condensate switch has shown continuity for 30 continuous sec.

Fault-Over/Under Voltage 8 No Auto Instantaneous voltage is out of range. **Controls shut down until resolved.

Fault-FP1 & 2 Snsr Error 11 Yes Hard or Soft If FP1 or 2 Sensor Error

AB

C &

AX

B A

dvan

ce

d F

au

lts Fault-Compressor Monitor 10 Yes Hard or Soft Open Crkt, Run, Start or welded cont

Non-CriticAXBSnsrErr 13 No Auto Any Other Sensor Error

CriticAXBSnsrErr 14 Yes Hard or Soft Sensor Error for EEV or HW

Alert-HotWtr 15 No Auto HW over limit or logic lockout. HW pump deactivated.

Fault-VarSpdPump 16 No Auto Alert is read from PWM feedback.

Not Used 17 No Auto IZ2 Com Fault. Autoreset upon condition removal.

Non-CritComErr 18 No Auto Any non-critical com error

Fault-CritComErr 19 No Auto Any critical com error. Auto reset upon condition removal

Alarm - Low Loop Pressure 21 No Auto Loop pressure is below 3 psi for more than 3 minutes

Alarm - Home Automation 1 23 No Auto Closed contact input is present on Dig 2 input - Text is configurable

Alarm - Home Automation 2 24 No Auto Closed contact input is present on Dig 3 input - Text is configurable

NOTES: *All codes >11 use long flash for tens digit and short flash for the ones digit. 20, 30, 40, 50 etc. are skipped!Alert’ is a noncritical sensor or function that has failed. Normal operation of the heat pump is maintained but service is desired at some point.



Code*Lockout

Reset/Remove

AB

C B

asi

c F

au

lts

Normal - No Faults OFF –

Fault - Input 1 No Auto

Fault - High Pressure 2 Yes Hard or Soft

Fault - Low Pressure 3 Yes Hard or Soft



Fault - Condensate Overflow 7 Yes Hard or Soft

Fault - Over/Under Voltage 8 No Auto

Fault - FP1 & FP2 Sensor Error 11 Yes Hard or Soft

NOTE: All codes >11 use long flash for tens digit and short flash for the ones digit. 20, 30, 40, 50, etc. are skipped.

Aurora Base Fault Codes (ABC Only)

Aurora Advanced Fault Codes (ABC + AXB Expansion Board)


78


Status LED (LED3, Green)

Description of Operation Fault LED, Green

Normal Mode ON






Emergency Shutdown Flash Code 6

On Peak Mode Flash Code 7


(Future Use) Flach Code 9

Configuration LED (LED2, Yellow)

Description of Operation Configuration LED, Yellow

No Software Overwritten ECM Setting

DIP Switch Overwritten Slow Flash


Reset Configuration Mode OFF

Aurora Base or Advanced Control Configuration andStatus Codes

9. Alarm Relay – The Alarm relay (ALM) is factory

connected to 24 VAC via jumper JW2. By cutting JW2,

ABC ALM becomes a dry contact connected to ABC

ALG. The Relay is field switchable between Factory

setting as an Alarm output or available for other uses.

10. Accessory Relay1 – A configurable, accessory relay

on the ABC is provided that can be cycled with the

compressor, blower, or the Dehumidifier (DH) input.

A third (factory) setting cycles the relay with the

compressor but delays the compressor and blower

output for 90 sec. Source pump or slow opening

solenoid valves in well systems or variable speed

primary pumping systems would be a prime use of

this feature.

Access Relay Operation SW2-4 SW2-5

Cycle with Blower ON ON

Cycle with Compressor OFF OFF

Water Valve Slow Opening ON OFF

Cycle with Comm. T-stat Hum Cmd OFF ON

11. Electric Heat EH1 – A digital 24VDC output is provided

for electric heat powering. UPC’s Default programming

has EH1 set for AUX/ELEC Heat operation and will be

controlled using the UPC’s internal P.I.D. logic. However

it can be changed by the BAS to be network controlled.

12. Electric Heat EH2 – A digital VDC output is provided

for field options converted from the original EH2

output. Default UPC program has the EH2 output set

for Network Control but can be changed by the BAS

to be controlled by the UPC’s internal P.I.D. logic.


1. Accessory Relay2 – A second, configurable, accessory

relay on the AXB is provided that can be cycled with

the compressor 1 or 2 , blower, or the Dehumidifier (DH)

input. This is to complement the Accessory 1 Relay on

the ABC board.

2. Analog Out – A standard 0-10VDC analog output is

provided. This output can be used to drive modulat-

ing dampers etc.

3. Variable Speed Pump or Modulating Water Valve (If applicable) - This input and output are provided

to drive and monitor a variable speed pump. The VS

pump output is a PWM signal to drive the variable

speed pump. The minimum and maximum level are set

using the AID Tool. 75% and 100% are the default set-

tings respectively. The VS data input allows a separate

PWM signal to return from the pump giving fault and

performance information. Fault received from the vari-

able speed pump will be displayed as E16. Modulat-ing Water Valve - This Variable speed PWM output is

provided to optionally drive a modulating water valve.

Through advanced design a 0-10VDC valve can be

driven directly from the VS pump output. The mini-

mum and maximum level are set in the same way as

the VS pump using the AID Tool. 75% and 100% are

the default settings respectively.

4. Loop Pump Slaving (If applicable) - This input and

output are provided so that two units can be slaved

together with a common flow center. When either unit

has a call for loop pump, both unit’s loop pump relays

and variable speed pumps are energized. The flow

center then can simply be wired to either unit. The

output from one unit should be routed to the input of

the other. If daisy chained up to 16 heat pumps can be

wired and slaved together in this fashion.

Position DIP 4 DIP 5 Description

1 ON ON Cycles with Fan or ECM (or G)

2 OFF ONCycles with CC1 first stage of compressor

or compressor spd 1-12

3 ON OFFCycles with CC2 second stage of

compressor or compressor spd 7-12

4 OFF OFF Cycles with DH input from ABC board

Aurora Advanced Control Configuration and Options (Future Availability on Select Models/Configurations)

79


1. Energy Monitoring (Standard Sensor Kit on ‘Advanced’ models) - The Energy Monitoring Kit

includes two current transducers (blower and electric

heat) added to the existing two compressor sensors so

that the complete power usage of the heat pump can

be measured. The BACview Tool provides configuration

detail for the type of blower motor and a line voltage

calibration procedure to improve the accuracy. This

real time power usage information can be displayed on

the AID Tool and is available thru network points when

using BACnet or N2 Open.

• Compressor Current 1

• Compressor Current 2

• Fan Current

• Aux Heat Current

• Pump Selection

• Voltage

• Compressor Watts

• Fan Watts

• Aux Heat Watts

• Pump Watts (VS Only)

2. Refrigerant Monitoring (optional sensor kit) - The

optional Refrigerant Monitoring Kit includes two

pressure transducers, and three temperature sensors,

heating liquid line, suction temperature and existing

cooling liquid line (FP1). These sensors allow the

measurement of discharge and suction pressures,

suction and liquid line temperatures as well as

superheat and subcooling. This information can be

displayed on the BACview Tool, or the network when

using BACnet and N2.

• Htg Liquid Line

• Clg Liquid Line

• Discharge pressure

• Suction Pressure

• Discharge Saturated Temp

• Suction Saturated Temperature

• Superheat

• SubCooling

3. Performance Monitoring (optional sensor kit, 036-144 only) - The optional Performance Monitoring Kit

includes: three temperature sensors, entering and

leaving water, leaving air temperature and a water

flow rate sensor. With this kit, heat of extraction and

rejection will be calculated. This requires configuration

using the BACview Tool for selection of water or

antifreeze.

• Leaving Air Temperature (supply)

• Alt Leaving Air Temperature (Supply)

• Entering Water Temperature

• Leaving Water Temperature

• Water Flow Meter (036-144 only)

• Entering Air Temperature (from zone sensor)

• Brine Selection (water/antifreeze)

• Heat of Extraction/Rejection

Aurora Advanced Control Optional Sensor Kits (Availability on Select Models/Configurations)


80


ZS Series RNet Sensor Overview

The ZS Series line of intelligent zone sensors provides the

function and flexibility you need to manage the conditions

important to the comfort and productivity of the zone

occupants. The ZS sensors are available in a variety of

zone sensing combinations to address your application

needs. These combinations include temperature, relative

humidity, and indoor air quality (carbon dioxide or VOCs

(Volatile Organic Compounds)). They are built to be

flexible allowing for easy customization of what the user/

technician sees. Designed to work with the Aurora UPC

controllers the ZS sensor line includes the ZS Base, ZS

Plus, ZS Pro and ZS Pro-F.

The UPC uses a proprietary communication called Rnet

to receive the space temperature from the zone sensor.

This is done using (2) 18 AWG twisted pair unshielded

cables for a total of 4 wires connected to the Rnet port.

The sensor gets its power from the UPC controller and

connecting multiple sensors to one UPC will allow for space

temperature averaging. The UPC can support one ZS Pro

or ZS Pro F with up to four ZS standard sensors wired to

the Rnet port on the UPC for a total of 5 zone sensors.

The sensors use a precise 10k ohm thermistor with less

than 0.18°F drift over a ten year span, this allows for less

maintenance or re-calibration after installation. The sensors

also have a hidden communication port for connecting

a BACview or local laptop that provides access to the

equipment for commissioning and maintenance. The table

below shows the features of each of the four sensors that

are currently available.

ZS Base

ZS Plus ZS Pro

ZS Pro-F

Features ZS Base ZS Plus ZS Pro ZS Pro-F

Temp, CO2, Humidity, and VOC Options √ √ √ √

Neutral Color √ √ √ √

Addressable/supports daisy chaining √ √ √ √

Hidden communication port √ √ √ √

Mounts on a standard 2” by 4” electrical box √ √ √ √

Occupancy Status indicator LED √ √ √

Push button occupancy override √ √ √

Setpoint adjust √ √ √

Large, easy to read LCD √ √

Alarm indicator √ √

°F to °C conversion button √

Options Part Number Part Number Part Number Part Number

Temperature Only ZSU ZSUPL ZSUP ZSUPF

Temp with CO2 ZSU-C ZSUPL-C ZSUP-C ZSUPF-C

Temp with Humidity ZSU-H ZSUPL-H ZSUP-H ZSUPF-H

Temp with Humidity, CO2 ZSU-HC ZSUPL-HC ZSUP-HC ZSUPF-HC

Temp, Humidity, VOC ZSU-HV ZSUPL-HV ZSUP-HV ZSUPF-HV

Temp with VOC ZSU-V ZSUPL-V ZSUP-V ZSUPF-V


81


RNet Sensor Physical and Electrical Data

Sensing Element Range Accuracy

Temperature (on non-Humidity models) -4° to 122° F (-20° C to 50° C) ±0.35° F (0.2° C)

Temperature (on Humidity models) 50° F to 104° F (10° C to 40° C) ±0.5° F (0.3° C)

Humidity 10% to 90% ±1.8% typical

CO2 400 to 1250 PPM

1250 to 2000 PPM

±30PPM or +/-3% of reading (greater of two)

±5% of reading plus 30 PPM

VOC 0 to 2,000 PPM ±100 PPM

Power Requirements Sensor Type Power Required

Temperature Only All Models 12 Vdc @ 8 mA

Temperature with Humidity All Models 12 Vdc @ 15 mA (idle) to 190 mA

(CO2 measurement cycle)

Temp with VOC, or Temp/VOC/Humidity All Models 12 Vdc @ 60 mA

Temp with CO2 , or Temp/ CO2/Humidity All Models12 Vdc @ 15 mA (idle) to 190 mA

(CO2 measurement cycle)

Power Supply A controller supplies the Rnet sensor network with 12 Vdc @ 210 mA. Additional

power may be required for your application. See sensor ZS Installation Guide

Communication 115 kbps Rnet connection between sensor(s) and controller

15 sensors max per Rnet network; 5 sensors max per control program

Local Access Port For connecting a laptop computer to the local equipment for maintenance and commissioning

Environmental Operating Range 32° to 122° F (0° - 50° C), 10% to 90% relative humidity, non-condensing

Mounting Dimensions Standard 4”x 2” electrical box using provided 6/32” x 1/2” mounting screws


82


82

The optional economizer requires Aurora Advanced Control with Aurora UPC. This provides an integrated heat pump and economizer control allowing an integrated solution with all economizer parameters, faults and sensors presented as points on the BAS when BACnet MS/TP, N2, or Lon are used. Although the Aurora UPC is required for economizer operation it can operate in the standalone mode without a BAS in those cases where an economizer is required but a BAS is not present.

The economizer utilizes three internal sensors plus the zone sensor: the outdoor temp or enthalpy, return air temp or en-thalpy, and discharge air temperature. The table below displays the 3 sensor options of the rooftop nomenclature: dry bulb sensors, enthalpy sensors or sensorless/network control options.

Economizer Enthalpy Operation with Aurora Controls

Economizer High Limit Method and Sensor Options

Economizer Sensor Locations

These sensors all connect into the Aurora Control System. The Aurora Touch service tool allows the user to select the High Limit Mode and view all pertinent temperatures and enthalpy levels. The setpoint of DB high limit is defined by the econo-mizer high limit operating mode. ASHRAE 90.1-2013 only allows the following high limit modes of operation: 1) Fixed dry bulb, 2) Differential dry bulb, 3) Fixed enthalpy with fixed dry bulb, 4) Differential enthalpy with fixed dry bulb. A fifth mode of sensorless/network control is available for applications when the high limit is controlled by BAS network sensors. See Economizer section for more detail.

83


• High voltage is correct and matches nameplate.

• Fuses, breakers and wire size correct.

• Low voltage wiring complete.

• Piping completed and water system cleaned and flushed.

• Air is purged from closed loop system.

• Isolation valves are open, water control valves or loop pumps wired.

• Condensate line open and correctly pitched.

• Transformer switched to 208V if applicable.

• Dip switches are set correctly.

• Blower rotates freely – foam shipping support has been removed.

• Blower speed correct.

• Air filter/cleaner is clean and in position.

• Service/access panels are in place.

• Return air temperature is between 50-80°F heating and 60-95°F cooling.

• Check air coil cleanliness to insure optimum performance. Clean as needed according to maintenance guidelines. To

obtain maximum performance the air coil should be cleaned before startup. A 10-percent solution of dishwasher

detergent and water is recommended for both sides of coil, a thorough water rinse should follow.

Startup StepsNOTE: Complete the Equipment Start-Up/Commissioning Check Sheet during this procedure. Refer to thermostat

operating instructions and complete the startup procedure.

1. Initiate a control signal to energize the blower motor. Check blower operation.

2. Initiate a control signal to place the unit in the cooling mode. Cooling setpoint must be set below room temperature.

3. Cooling will energize after a time delay. Check for correct rotation of scroll compressors in 3 phase applications.

Incorrect rotation will cause low refrigerant pressures and possibly unusual noise. Switch any two power leads at the

line voltage supply.

4. Be sure that the compressor and water control valve or loop pump(s) are activated.

5. Verify that the water flow rate is correct by measuring the pressure drop through the heat exchanger using the P/T

plugs and comparing to the pressure drop table.

6. Check the temperature of both the supply and discharge water (Refer to Operating Parameters tables).

7. Check for an air temperature drop of 15°F to 25°F across the air coil, depending on the blower speed and entering

water temperature.

8. Decrease the cooling set point several degrees and verify high-speed blower operation (variable speed ECM only).

9. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop

pumps deactivate.

10. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature.

11. Heating will energize after a time delay.

12. Check the temperature of both the supply and discharge water (Refer to Unit Operating Parameters tables).

13. Check for an air temperature rise of 20°F to 35°F across the air coil, depending on the blower speed and entering

water temperature.

14. If auxiliary electric heaters are installed, increase the heating setpoint until the electric heat banks are sequenced on.

All stages of the auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode.

Check amperage of each element.

15. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop

pumps deactivate.

16. During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required.

17. Set system to desired normal operating mode and set temperature to maintain desired comfort level.

18. Instruct the owner/operator in the proper operation of the thermostat and system maintenance.

NOTE: Be certain to fill out and forward all warranty registration papers.

Unit Startup

Before Powering Unit, Check The Following:NOTE: Remove and discard the compressor shipping bolts. The bolts can then be discarded.

84


Operating Limits

85


Damper Pressure Drop

Models Tons CFM

Economizer Dampers dP

100% OA [in wg]

100% RA [in wg]

036-038 3900 0.010 0.0101200 0.010 0.0101400 0.012 0.010

048-049 41200 0.010 0.0101600 0.013 0.0102000 0.024 0.012

060-064 51600 0.013 0.0102000 0.024 0.0122400 0.031 0.018

070-072 62000 0.024 0.0122400 0.031 0.0183000 0.044 0.024

096 82800 0.024 0.0103200 0.026 0.0103600 0.031 0.010

120 103200 0.026 0.0104000 0.041 0.0124800 0.060 0.017

144 124000 0.041 0.0124800 0.060 0.0175600 0.075 0.028

180 154800 0.010 0.0106000 0.012 0.0107200 0.020 0.012

240 206400 0.016 0.0118000 0.024 0.0209600 0.036 0.025

300 258000 0.024 0.02010000 0.040 0.02712000 0.060 0.040

360 3010000 0.040 0.02712000 0.060 0.04014000 0.080 0.060

7/26/2017

86


Pressure Drop

Model GPMPressure Drop (psi)

30°F 50°F 70°F 90°F 110°F

Sin

gle

Sp

ee

d C

om

pre

sso

r

036

5.0 1.0 1.0 0.9 0.8 0.87.0 2.1 1.9 1.8 1.7 1.69.0 3.6 3.3 3.0 2.8 2.612.0 6.3 5.9 5.5 5.1 4.8

048

6.0 1.1 1.0 1.0 0.9 0.89.0 2.3 2.1 2.0 1.9 1.712.0 3.9 3.7 3.4 3.2 3.016.0 6.7 6.3 5.9 5.5 5.1

060

9.0 2.4 2.2 2.1 2.0 1.812.0 3.9 3.6 3.4 3.2 2.915.0 5.7 5.3 5.0 4.7 4.320.0 9.5 8.9 8.3 7.8 7.2

070

12.0 3.0 2.8 2.6 2.4 2.215.0 4.4 4.0 3.8 3.5 3.318.0 6.0 5.5 5.1 4.8 4.424.0 9.7 9.1 8.5 7.9 7.3

Du

al

Cap

acit

y C

om

pre

sso

r

038

5.0 1.2 1.2 1.1 1.0 1.07.0 2.2 2.1 1.9 1.8 1.79.0 3.4 3.2 3.0 2.8 2.611.0 4.9 4.6 4.3 4 3.7

049

6.0 1.2 1.2 1.1 1.0 1.09.0 2.4 2.2 2.1 2.0 1.812.0 3.9 3.6 3.4 3.2 2.915.0 5.7 5.3 5 4.7 4.3

064

8.0 1.8 1.7 1.6 1.4 1.312.0 3.8 3.5 3.3 3.0 2.816.0 6.5 6.0 5.6 5.2 4.820.0 9.7 9.1 8.5 8.0 7.4

072

12.0 3.2 3.0 2.8 2.6 2.415.0 4.5 4.2 4.0 3.7 3.418.0 6.0 5.7 5.3 4.9 4.621.0 7.8 7.3 6.8 6.4 5.9

Tw

o C

om

pre

sso

r

09612.0 2.1 2.0 1.9 1.9 1.818.0 4.7 4.4 4.1 3.8 3.624.0 8.0 7.7 7.4 7.1 6.9

12016.0 2.1 1.8 1.4 1.1 0.722.0 3.8 3.5 3.1 2.8 2.428.0 5.7 5.4 5.0 4.7 4.3

14424.0 4.1 3.7 3.2 2.8 2.430.0 5.9 5.5 5.0 4.6 4.236.0 8.8 8.4 7.9 7.5 7.1

18022.0 1.5 1.4 1.2 1.1 1.034.0 4.0 3.8 3.7 3.5 3.445.0 6.4 6.3 6.1 6.0 5.9

24030.0 0.9 0.8 0.8 0.7 0.645.0 2.2 2.1 1.9 1.8 1.660.0 3.5 3.3 3.1 2.9 2.4

300 35.0 1.8 1.6 1.3 1.1 0.850.0 5.4 5.2 4.9 4.7 4.475.0 10.4 10.1 9.9 9.6 9.4

36050.0 5.4 5.2 4.9 4.7 4.470.0 8.9 8.7 8.4 8.2 7.990.0 14.8 14.5 14.3 14.0 13.8

10/13/16

87


Reference Calculations

Legend and NotesABBREVIATIONS AND DEFINITIONS:

cfm = airflow, cubic feet/minute

EWT = entering water temperature, Fahrenheit

gpm = water flow in gallons/minute

WPD = water pressure drop, psi and feet of water

EAT = entering air temperature, Fahrenheit

(dry bulb/wet bulb)

HC = air heating capacity, MBtu/h

TC = total cooling capacity, MBtu/h

SC = sensible cooling capacity, MBtu/h

kW = total power unit input, kilowatts

HR = total heat of rejection, MBtu/h

HE = total heat of extraction, MBtu/h

HWC = hot water generator capacity, MBtu/h

EER = Energy Efficient Ratio

= BTU output/Watt input

COP = Coefficient of Performance

= Btu output/Btu input

LWT = leaving water temperature, °F

LAT = leaving air temperature, °F

TH = total heating capacity, MBtu/h

LC = latent cooling capacity, MBtu/h

S/T = sensible to total cooling ratio

Notes (Refer to Performance Data tables)

• Performance ratings are based on 80°F DB / 67°F WB EAT for cooling and 70°F DB EAT for heating.

• Three flow rates are shown for each unit. The lowest flow rate shown is used for geothermal open loop/well water

systems with a minimum of 50°F EWT. The middle flow rate shown is the minimum geothermal closed loop flow rate.

The highest flow rate shown is optimum for geothermal closed loop systems and the suggested flow rate for boiler/

tower applications.

• The hot water generator numbers are based on a flow rate of 0.4 gpm/ton of rated capacity with an EWT of 90°F.

• Entering water temperatures below 40°F assumes 15% antifreeze solution.

• For non-standard EAT conditions, apply the appropriate correction factors on (Refer to Correction Factor Tables).

• Interpolation between EWT, gpm, and cfm data is permissible.

Heating Calculations: Cooling Calculations:

LWT = EWT +

LAT(DB) = EAT(DB) -

LC = TC - SC

S/T =

HR

gpm x 500

SC

cfm x 1.08

SC

TC

HE

gpm x 500LWT = EWT -

LAT = EAT +

TH = HC + HWC

HC

cfm x 1.08

88


Compressor Resistance

Thermistor Resistance

Compressor Resistance Chart208-230/60/3 460/60/3

Model208-230/60/1

Run Start

Sin

gle

S

pe

ed

036 0.95 - 1.09 1.81 - 2.09 1.77 - 2.04 7.57 - 8.71042 0.83 - 0.95 1.54 - 1.78 1.42 - 1.64 5.46 - 6.28048 0.51 - 0.59 1.13 - 1.31 0.96 - 1.10 3.88 - 4.46060 0.42 - 0.48 0.73 - 0.85 0.63 - 0.73 2.98 - 3.42070 0.33 - 0.39 0.90 - 1.04 0.56 - 0.64 2.34 - 2.70

Du

al

Cap

acit

y 038 0.82 - 0.94 1.41 - 1.63 1.42 - 1.64 5.46 - 6.28049 0.48- 0.56 1.73 - 1.99 0.96 - 1.10 3.88 - 4.46064 0.36 - 0.42 1.52 - 1.74 0.63 - 0.73 2.98 - 3.42072 0.32 - 0.36 1.72 - 1.98 0.56 - 0.64 2.34 - 2.70

Tw

o

Co

mp

ress

or

096 0.96 - 1.10 3.88 - 4.46120 0.63 - 0.73 2.98 - 3.42144 0.56 - 0.64 2.34 - 2.70180 0.47 - 0.54 2.30 - 2.64181 0.47 - 0.54 2.30 - 2.64

240 0.33 - 0.39 1.28 - 1.48300 0.33 - 0.39 1.09 - 1.25360 0.20 - 0.23 0.77 - 0.89

7/27/17

Thermistor Resistance

Thermistor Resistance (10k Ohm) for FP1, FP2, HWL, LWT, LLT, and EWT

Temperature (°F) Resistance (Ohms)5 75757-7011714 57392-5323423 43865-4077132 33809-3148741 26269-2451350 20570-1923059 16226-1519668 12889-1209377 10310-968886 8300-781295 6723-6337104 5480-5172113 4490-4246122 3700-3504131 3067-2907140 2554-2424149 2149-2019

7/27/17

89


Should a major problem develop, refer to the following information for possible causes and corrective steps.

If compressor won’t run:1. The fuse may be open or the circuit breaker is tripped.

Check electrical circuits and motor windings for shorts or grounds. Investigate for possible overloading. Replace fuse or reset circuit breakers after fault is corrected.

2. Supply voltage may be too low. Check it with avolt meter.

3. Control system may be faulty. Check control for correct wiring of thermostat or aquastat and check the 24 volt transformer for proper voltage.

4. Wires may be loose or broken. Replace or tighten.5. The low pressure switch may have tripped due to one or

more of the following: a) Heating 1) Plugged heat exchanger on source side 2) Water flow source side - (Low) 3) Water too cold source side 4) Low refrigerant b) Cooling 1) Plugged heat exchanger on load side 2) Water flow load side - (Low) 3) Water too cold load side 4) Low refrigerant6. The high pressure switch may have tripped due to one

or more of the following: a) Heating 1) Plugged heat exchanger on load side 2) Low water flow load side 3) Water too warm load side b) Cooling 1) Plugged heat exchanger on source side 2) Low water flow on source side 3) Water too warm source side7. The compressor overload protection may be open.8. The internal winding of the compressor motor may

be grounded to the compressor shell. If so, replace the compressor.

9. The compressor winding may be open or shorted. Disconnect power. Check continuity with ohm meter. If the winding is open, replace the compressor.

If sufficient cooling or heating is not obtained:1. Check control for improper location or setting.2. Check for restriction in water flow.3. Check refrigerant subcooling and superheat for proper

refrigerant charge and expansion valve operation.4. The reversing valve may be defective and creating a

bypass of refrigerant. If the unit will not heat, check the reversing valve coil.

If the unit operation is noisy:1. Check compressor for loosened mounting bolts. Make

sure compressor is floating free on its isolator mounts. Check for tubing contact with the compressor or other surfaces. Readjust it by bending slightly.

2. Check screws on all panels.3. Check for chattering or humming in the contactor or

relays due to low voltage or a defective holding coil. Replace the component.

4. Check for proper installation of vibration absorbing material under the unit.

5. Check for abnormally high discharge pressures.6. Compressor rotation incorrect

Aurora Control SystemNOTE: Refer to the Aurora Base Control Application and

Troubleshooting Guide and the Instruction Guide: Aurora

Interface and Diagnostics (AID) Tool for additional information.

To check the unit control board for proper operation:

1. Disconnect thermostat wires at the control board.

2. Jumper the desired test input (Y1, Y2, W, O or G) to the R

terminal to simulate a thermostat signal.

3. If control functions properly:

• Check for thermostat and field control wiring (use

the diagnostic inputs mode).

4. If control responds improperly:

• Ensure that component being controlled is

functioning (compressor, blower, reversing

valve, etc.).

• Ensure that wiring from control to the component

is functioning (refer to the LED Definition table

below and use the diagnostic outputs mode).

• If steps above check properly, replace unit control.

Refrigerant Systems To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Compare the change in temperature on the air side as well as the water side to the Operating Parameters tables. If the unit’s performance is not within the ranges listed, and the airflow and water flow are known to be correct, gauges should then be installed and superheat and subcooling numbers calculated. If superheat and subcooling are outside recommended ranges, an adjustment to the refrigerant charge may be necessary.

NOTE: Refrigerant tests must be made with hot water generator turned “OFF”. Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit.

Troubleshooting

90


Check One Start up/Check-out for new installation ❑ Troubleshooting Problem:___________________________________❑

1. FLOW RATE IN GPM (COAXIAL HEAT EXCHANGER)

Water In Pressure: a.______ PSIWater Out Pressure: b.______ PSIPressure Drop = a - b c.______ PSIConvert Pressure Drop to Flow Rate (refer to Pressure Drop table) d.______ GPM

2. TEMPERATURE RISE OR DROP ACROSS COAXIAL HEAT EXCHANGER

COOLING HEATINGWater In Temperature: e.______ °F e.______ °FWater Out Temperature: f. ______ °F f. ______ °FTemperature Difference: g.______ °F g.______ °F

3. TEMPERATURE RISE OR DROP ACROSS AIR COIL

COOLING HEATINGAir In Temperature: h.______ °F h.______ °FAir Out Temperature: i. ______ °F i. ______ °FTemperature Difference: j. ______ °F j. ______ °F

4. HEAT OF REJECTION (HR) / HEAT OF EXTRACTION (HE) CALCULATION

HR or HE = Flow Rate x Temperature Difference x Brine Factor* d. (above) x g. (above) x 485 for Methanol or Environol, 500 for water*Heat of Extraction (Heating Mode) = btu/hrHeat of Rejection (Cooling Mode) = btu/hrCompare results to Capacity Data Tables

Note: Steps 5 through 8 need only be completed if a problem is suspected

5. WATTSCOOLING HEATING

Volts: m._____ VOLTS m.______ VOLTSTotal Amps (Comp. + Fan): n. _____ AMPS n. ______ AMPSWatts = m. x n. x 0.85 o. _____ WATTS o. ______ WATTS

6. CAPACITYCooling Capacity = HR. - (o. x 3.413) p. _____ btu/hrHeating Capacity= HE. + (o. x 3.413) p. _____ btu/hr

7. EFFICIENCYCooling EER = p. / o. q. _____ EERHeating COP = p. / (o. x 3.413) q. _____ COP

8. SUPERHEAT (S.H.) / SUBCOOLING (S.C.) COOLING HEATING

Suction Pressure: r. ______ PSI r. ______ PSISuction Saturation Temperature: s. ______ °F s. ______ °FSuction Line Temperature: t. ______ °F t. ______ °FSuperheat = t. - s. u. _____ °F u. ______ °F

Head Pressure: v. ______ PSI v. ______ PSIHigh Pressure Saturation Temp.: w. _____ °F w. _____ °FLiquid Line Temperature*: x. ______ °F x. ______ °FSubcooling = w. - x. y. ______ °F y. ______ °F

* Note: Liquid line is between the coaxial heat exchanger and the expansion valve in the cooling mode; between the air coil and the expansion valve in the heating mode.

Company Name: _________________________________Technician Name: ________________________________Model No: ______________________________________Owner’s Name: __________________________________Installation Address: ______________________________

Company Phone No: ______________________________Date: __________________________________________Serial No:_______________________________________Open or Closed Loop: _____________________________Installation Date: _________________________________

Startup and Troubleshooting Form

91


COOLING CYCLE ANALYSIS

Hot WaterGenerator

-

EXPANSIONVALVE

AIRCOIL

°F

PSI

°F

PSI

BRINE IN BRINE OUT

BRINE IN BRINE OUT

COMPRESSOR

DISCHARGE

SUCTION

Subcooling

Superheat

REVERSINGVALVE

PSI

°F

SAT °F=

PSI = SAT F

F°FLIQUID LINE

COAXSOURCE

hook up pressure gauges unless there appears to be a performance problem.

Line Voltage:

Loop: OpenUnit Amp Draw:

Closed

COAXSOURCE

HEA ANALYSIS

-

EXPANSIONVALVE

°F AIRCOIL

°F

COMPRESSOR

DISCHARGE

SUCTION

Subcooling

Superheat

REVERSINGVALVE

PSI

°F

SAT °F=

PSI = SAT F

FFLIQUID LINE

Line Voltage:

Loop: OpenUnit Amp Draw:

Closed

Dealer:

Phone #: Date:

Problem:

Model #:

Serial #:

Startup/ roubleshooting Form

°F

Hot WaterGenerator

°F °F

°F

PSI

°F

PSI °F

°F °F

Controls Info:

ABC Version:

AXB Version:

IZ2 Version:

T-Stat Version:

Installed Sensors:

Water to Water Application

COAXLOAD

BRINE IN BRINE OUT

°F

PSI

°F

PSI

Water to Water Application

COAXLOAD

BRINE IN BRINE OUT

°F

PSI

°F

PSI

92


Water Coil Maintenance1. Keep all air out of the water. An open loop system

should be checked to ensure that the well head is not

allowing air to infiltrate the water line. Lines should

always be airtight.

2. Keep the system under pressure at all times. It is

recommended in open loop systems that the water

control valve be placed in the discharge line to prevent

loss of pressure during off cycles. Closed loop systems

must have positive static pressure.

NOTE: On open loop systems, if the installation is in an area

with a known high mineral content (125 PPM or greater) in

the water, it is best to establish with the owner a periodic

maintenance schedule so the coil can be checked regularly.

Should periodic coil cleaning be necessary, use standard

coil cleaning procedures which are compatible with either

the cupronickel or copper water lines. Generally, the more

water flowing through the unit the less chance for scaling.

Other MaintenanceFilters

Filters must be clean to obtain maximum performance.

They should be inspected monthly under normal operating

conditions and be replaced when necessary. Units should

never be operated without a filter.

Condensate Drain

In areas where airborne bacteria produce a slime in the

drain pan, it may be necessary to treat chemically to

minimize the problem. The condensate drain can pick up

lint and dirt, especially with dirty filters. Inspect twice a

year to avoid the possibility of overflow.

Blower Motors

Blower motors are equipped with sealed ball bearings and

require no periodic oiling.

Air Coil

The air coil must be cleaned to obtain maximum

performance. Check once a year under normal operating

conditions and, if dirty, brush or vacuum (with a brush

attachment) clean. Care must be taken not to damage the

aluminum fins while cleaning.

Obtaining PartsWhen ordering service or replacement parts, refer to the

model number and serial number of the unit as stamped on

the serial plate attached to the unit. If replacement parts are

required, mention the date of installation of the unit and the

date of failure, along with an explanation of the malfunctions

and a description of the replacement parts required.

In-Warranty Material ReturnMaterial may not be returned except by permission

of authorized warranty personnel. Contact your local

distributor for warranty return authorization and assistance.

CAUTION: Fin edges are sharp.

Preventive Maintenance

Replacement Parts

93


Notes

94


Revision Guide

Pages: Description: Date: By:

9-21 Updated Dimensional Data 20 Nov 2017 MA

All Updated Dimensional data, weights table, misc. updates 27 Oct 2017 MA

All Product Updates - Schematics, Nomenclature, Data Tables 28 July 2017 MA

All Literature Creation 9 Feb. 2017 JM

Manufactured by

WaterFurnace International, Inc.

9000 Conservation Way

Fort Wayne, IN 46809

www.waterfurnace.com

©2017 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and

reserves the right to change design and specifi cations without notice.

Product: Versatec Packaged Rooftop

Type: Water Source/Geothermal Heat Pump

Size: Commercial 3-30 Ton

Document: Installation ManualIM1250AU 11/17

*IM1250AU*

Documents

PACKAGED ROOFTOP - WaterFurnace · Water Piping All piping access is within the curb in the compressor section. Piping is usually designed as ‘reverse return’ to equalize flow